Materials Test Engineer

Commonwealth Fusion Systems•Somerville, MA

3d•Onsite

About The Position

The Materials Department at CFS supports design engineers, supply chain, and manufacturing by guiding the selection of materials that meet design intent, executing testing, validation, and creation of design curves for materials, and conducting R&D to develop new materials and processes to enable fusion power deployment. The work is undertaken in support of delivering SPARC, the net energy tokamak under construction in Devens, MA, and ultimately in designing the ARC fusion power plant. These devices pose unique materials challenges including neutron fluxes produced by deuterium-tritium fusion, high heat and mechanical loads driven by high magnetic fields and cryogenic environment, molten salt coolant systems, and manufacturing challenges driven by components’ sizing and processes such as welding and other joining methods. To support this mission, the CFS Materials Department is seeking a Materials Test Engineer with experience in electrical characterization of insulating materials and sub-assemblies. The ideal candidate has a background in materials engineering and experience with electrical characterization and testing. This role combines material design with functional testing, specifically focusing on the intersection of structural composites and their behavior under high voltage in extreme environments. They will actively engage in the entire lifecycle of a composite system, from identifying materials, selecting architectures and processes, to designing the custom high-voltage test stands required to validate them for fusion applications.

Requirements

BS in Materials science engineering, mechanical engineering, applied physics or related field
5+ years of relevant experience
Hands-on experience with process-structure-properties fundamentals of engineering composites (e.g., fiber-reinforced polymers)
Experience in high-voltage and insulation-related testing, including the ability to troubleshoot test setups, instrumentation, and unexpected test behavior
Experience with Paschen curves, dielectric breakdown mechanisms, and the fundamentals of electricity
Proficiency in CAD (e.g., NX, Solidworks) for the design of specialized electrical test fixtures and custom test stand components
Experience managing multiple test requests and priorities independently, including resource estimation and schedule communication
Strong ability to analyze complex datasets to identify trends and performance risks in material insulation systems
Experience mentoring junior engineers or technicians on electrical testing methods and laboratory safety protocols
Understanding process-structure-properties-performance principles for composites
Able to think creatively and possess strong troubleshooting and problem solving skills
Demonstrated ability to work effectively cross-functionally
Excellent organizational skills including prioritization of multiple concurrent projects
Ability to break down complex problems into smaller deliverables that add value
Extended activities such as typing, standing, and sitting
Dedication to safety to mitigate hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, metallographic etchants and cryogenics
Willingness to travel or work required nights/weekends/on-call occasionally

Nice To Haves

Experience with electrical testing in extreme environments (high temperature, cryogenic, vacuum)
Prior experience authoring internal material specifications or working with international materials standards (ASTM, ISO etc)
Familiarity with the effects of radiation and plasma on the electrical performance of composite materials

Responsibilities

Evaluate, test and qualify materials and components for structural and functional applications within SPARC and ARC
Own the execution and interpretation of electrical testing across coupon, sub-assembly, and component-level hardware, including dielectric, impulse, and Paschen testing
Author and maintain materials test specifications, SOPs, and calibration practices for testing equipment and test stands.
Review, interpret, and report materials property data into version-controlled databases, ensuring high quality and actionable recommendations for design teams
Design, develop, and support custom electrical characterization test setups, instrumentation, and other custom test stands and test methods to meet evolving company needs
Participate in the product design-build-test-learn cycles and retire technical risks by translating performance requirements into test plans and specifications
Support the selection, development, and qualification of composite materials, and translate performance requirements into material property specifications
Work closely with other CFS teams including: Safety team to manage hazards in existing and new experiments, Adjacent R&D teams to optimally share pooled resources including equipment and personnel, Supply chain team to procure new equipment and materials, Test validation and analysis for data generated by materials test operators and R&D technicians