Mechanical Design Engineer

Zap Energy•Everett, WA

About The Position

Zap Energy is seeking a Mechanical Design Engineer to support the Zap Modular Reactor (ZMR) program. The engineer will join an integrated project team delivering a liquid-metal-cooled fission reactor as part of Zap’s integrated nuclear mission. The role involves designing components and systems for the high-temperature reactor and liquid-metal cooling teams, taking concepts from initial layout through detailed design, fabrication, and installation. It also involves identifying and solving ill-defined first-of-a-kind problems within a collaborative team.

Requirements

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Nuclear Engineering, or a related field from an ABET-accredited program.
At least 5 years of experience in mechanical design and delivery of complex systems, including nuclear reactors, flight vehicles, or industrial plants.
Experience with a PDM/PLM system, such as Windchill, Teamcenter, or SolidWorks PDM, including revision control, ECO/ECN processes, and release workflows.
Proficiency in 3D CAD, such as SolidWorks, Creo, NX, or Inventor, including part and assembly modeling, detailed drawings, GD&T, and design for manufacturability.
Working knowledge of ASME Codes & Standards, including BPVC Section VIII, applied to mechanical design.
Excellent technical writing and the ability to clearly present complex information to internal and external stakeholders, including regulators.
Strong commitment to engineering safety, quality, and ethical standards.
Strong problem-solving skills, spatial reasoning, and attention to detail.
Effective verbal and written communication and ability to collaborate in a multidisciplinary team.
Familiarity and competence with basic program management processes and tools.
Adaptability, resilience, and commitment to continuous learning.

Nice To Haves

Experience with advanced non-water-cooled nuclear reactors.
Working experience with ASME BPVC Section III Division 5.
Familiarity with FEA tools such as ANSYS.
Knowledge of modern software engineering practices and programming languages such as Python.
Professional Engineer (PE) license.
Self-starter attitude and practical, outside-the-box problem solving.

Responsibilities

Plan, organize, and lead mechanical design efforts within a graded quality program.
Create 3D CAD models, assemblies, and detailed drawings, including GD&T, for ZMR systems and testing platforms.
Use skeleton and top-down modeling, manage interfaces, and keep reactor-scale assemblies stable and traceable.
Select applicable design and fabrication codes and standards for components, including ASME B31.1/B31.3, ASME Y14.5, AWS D1.1 or AWS/ASME welding standards, and ASME BPVC Sections VIII and III.
Design high-temperature pressure-boundary components and piping to ASME BPVC requirements in partnership with analysis engineers.
Manage interfaces among systems such as the vessel, internals, piping, instrumentation, and shielding, and perform interference and clearance checks.
Design mechanical actuation systems, such as reactivity control systems.
Define analysis needs and use FEA results, such as ANSYS, and design calculations to guide design iterations.
Create and maintain CAD models, drawings, and bills of materials for ZMR system development, and perform design-level calculations to size and verify components.
Write high-quality documentation with rigor appropriate to project stage and quality requirements.
Plan work packages to meet schedule milestones.
Review and approve engineering deliverables, including supplier submittals and drawings.
Collaborate with analysis, testing, and integration teams to keep the design basis and safety basis aligned.
Incorporate analysis and test feedback into designs, considering manufacturability, assembly, and maintainability.
Identify and evaluate engineering trade-offs for the design and safety bases, particularly when they conflict.
Identify testing activities that can simplify or increase confidence in the design.
Identify opportunities for engineering and process improvement and implement solutions.
Represent the company technically in supplier collaborations, including drawing and specification release, fabrication support, and review of manufacturing documentation.
Perform work within a graded quality assurance program and implement appropriately scaled solutions to improve execution efficiency, especially across organizational quality-assurance functions.