Mechanical Design Engineer

Zap Energy•Everett, WA

11d•$130,000 - $190,000

About The Position

Zap Energy is seeking a Mechanical Design Engineer to support the Zap Modular Reactor (ZMR) program. The role is part of an integrated project team delivering a liquid metal cooled fission reactor in support of Zap’s integrated nuclear mission. The engineer will design components and systems for the high-temperature reactor and liquid metal cooling teams, taking concepts from initial layout through detailed design, fabrication, and installation. The position involves solving ill-defined first-of-a-kind problems and requires a collaborative approach. The engineer will own and contribute to mechanical design efforts within a graded quality program, creating and maintaining CAD models, drawings, and bills of materials; performing design-level calculations; and producing project documentation. The role includes coordination with analysis, testing, integration, and supplier teams, review and approval of engineering deliverables, and work to improve engineering execution and quality processes. Employment may be conditioned upon the ability to obtain export authorization.

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, including revision control, ECO/ECN processes, and release workflows.
Proficiency in 3D CAD, 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.
Familiarity with FEA tools such as ANSYS to support design iteration.
Excellent technical writing skills and ability to clearly present complex information to internal and external stakeholders, including regulators.
Strong commitment to safety, quality, and ethical standards in engineering.
Strong problem-solving skills, spatial reasoning, and attention to detail.
Ability to work collaboratively in a multidisciplinary team environment.
Effective verbal and written communication skills.

Nice To Haves

Experience with advanced non-water-cooled nuclear reactors.
Working experience with ASME BPVC Section III Division 5.
Knowledge of modern software engineering practices and programming languages such as Python.
Professional Engineer (PE) license.
Familiarity and competence with basic program management processes and tools.
Self-starter attitude, practical outside-the-box thinking, adaptability, resilience, and commitment to continuous learning.

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/top-down modeling, manage interface control, and keep reactor-scale assemblies stable and traceable.
Select applicable codes and standards for component design and fabrication, including ASME piping, GD&T, welding, and pressure vessel standards.
Design high-temperature pressure-boundary components and piping to ASME BPVC requirements in partnership with analysis engineers.
Manage interfaces among systems such as vessels, internals, piping, instrumentation, and shielding, including interference and clearance checks.
Design mechanical actuation systems, such as reactivity control systems.
Define analysis needs and use FEA results and design calculations to drive design iterations.
Maintain CAD models, drawings, and bills of materials, and perform design-level calculations to size and verify components.
Write project documentation with rigor appropriate to the project stage and required quality level.
Plan work packages to meet schedule milestones.
Review and approve engineering deliverables, including supplier submittals and drawings.
Coordinate 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, particularly when design-basis and safety-basis considerations conflict.
Identify testing activities that could simplify or increase confidence in the design.
Identify and implement engineering and process improvements.
Represent the technical team 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 sized efficiency improvements, especially for cross-organizational quality assurance functions.