FEA Engineer III

Thea Energy•Kearny, NJ
•$120,000 - $155,000

About The Position

Thea Energy is seeking a highly motivated and experienced Finite Element Analyst to perform complex analysis supporting the design, optimization, and verification of thermal, structural, and magnetic requirements for its stellarator systems. The role focuses on complex multi-domain and nonlinear analyses, advanced material and weld modeling, structural optimization, and providing data-driven recommendations to justify critical design decisions. The analyst will develop finite element models and simulations for major stellarator systems and prototyping activities, contribute to design improvements, and provide technical guidance and peer review for junior analysts.

Requirements

  • At least 4 years of industry or academic experience performing Finite Element Analysis using commercial software packages.
  • Experience scripting and building tools around commercial FEA tools.
  • Demonstrated ability to solve complex engineering problems and identify root causes through meticulous analysis.
  • Proven experience developing first-of-its-kind components or systems.
  • Experience with the cryogenic behavior of materials and welds.
  • Strong communication and collaboration skills and ability to work as a team player.
  • Adaptability, exceptional work ethic, and a continuous improvement mindset.

Nice To Haves

  • A strong background in mechanical engineering, applied mechanics, materials, and simulation.
  • Experience with advanced nonlinear analysis, material and weld modeling, and structural optimization.

Responsibilities

  • Create complex finite element models, including advanced nonlinear contacts, plasticity, and large deformations, to support stellarator system design and prototyping.
  • Develop and analyze multi-domain models involving thermal, mechanical, vibration, and magnetic loads.
  • Own complex multi-domain and nonlinear analyses and define advanced material and weld modeling parameters.
  • Drive structural optimization and justify critical design decisions to engineering leadership.
  • Provide technical guidance and peer review for junior analysts (Eng I/II) to ensure model accuracy and best practices.
  • Optimize structures for performance under loading conditions while minimizing weight and maximizing maintainability.
  • Participate in the design process and identify opportunities to improve performance, cost, and maintainability.
  • Identify material property development required to ensure accurate analysis.

Benefits

  • Comprehensive health benefits, including medical, dental, and vision.
  • Employee equity stock options.
  • 20 days PTO.
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