Principal Mechanical Engineer - Web Handling

Commonwealth Fusion Systems•Milpitas, CA

22h

About The Position

Commonwealth Fusion Systems is seeking a Principal Mechanical Engineer specializing in web handling and roll-to-roll (R2R) systems. This company-wide technical authority will shape the technical direction, architecture, and deployment of high-precision web transport systems operating in varied thermal environments. The role leads complex, ambiguous, cross-functional initiatives affecting the company’s R&D and manufacturing roadmap, and combines independent technical leadership in web dynamics and precision mechatronics with division-wide standards, risk mitigation, and engineering mentorship. The engineer will architect next-generation R2R equipment, research emerging web-handling technologies, and translate scientific R&D objectives into engineering architectures spanning mechanical design, process physics, electrical hardware, and closed-loop controls. The role also drives modeling and validation of web dynamics, establishes design and testing standards, advances novel transport concepts, oversees supplier partnerships, and mentors engineers across experience levels.

Requirements

Master’s or PhD in Mechanical Engineering, Mechatronics, or a related field, or equivalent specialized industrial experience.
15+ years of experience as a recognized technical leader in architectural design, scaling, and implementation of complex web-handling, roll-to-roll, or converting equipment.
Authoritative knowledge of web-handling physics, including closed-loop tension control, winder dynamics, lateral guiding, roller traction, nip mechanics, load-cell integration, and substrate stress distribution.
Ability to integrate mechanical systems with advanced motion controls, power electronics, and thermal management systems.
Track record of bringing first-of-a-kind continuous-processing capital equipment from concept through commissioning and high-yield operational scale.
Ability to drive technical consensus and lead multidisciplinary teams without formal line-management authority.
Ability to occasionally lift up to 50 lbs.
Ability to stoop, climb, stand, or sit for extended periods.
Dedication to safety in environments that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, and cryogenics.
Willingness to travel or work required nights, weekends, or on-call occasionally.
Must comply with U.S. laws concerning export-controlled or protected technologies and information; any employment offer is contingent on this compliance.

Nice To Haves

Advanced mastery of 3D CAD platforms such as SolidWorks and/or NX, together with expertise in multi-body dynamics, non-linear FEA, and finite-difference web simulations.
Specialized experience handling narrow metal tapes, high-strength alloys, or delicate multi-layer composite webs.
Deep familiarity with tuning multi-axis servo drives, dancer-control algorithms, and adaptive tension loops.

Responsibilities

Serve as chief architect for next-generation roll-to-roll equipment, dynamic tension systems, precision accumulators, and high-speed winders and unwinders.
Research, evaluate, and benchmark web-handling, winding, and unwinding technologies to inform tool architecture and roadmap decisions.
Translate scientific R&D objectives into engineering architectures across mechanical design, process physics, electrical hardware, and closed-loop controls.
Lead dynamic modeling, web-physics analysis, and experimental validation to resolve web defects such as thermal buckling, lateral drift, scratching, and tension transients.
Establish company-wide engineering standards, design guidelines, and testing methods for web handling, precision roller design, bearing selection, and mechatronics.
Develop novel mechanical concepts, dynamic guiding schemes, and non-contact web transport modules for use inside temperature zones.
Identify, evaluate, and mitigate high-impact technical risks across major equipment initiatives, including contingency paths and robust design margins.
Audit, qualify, and direct global suppliers and contract manufacturers for specialized R2R subassemblies, precision-ground rollers, custom surface coatings, and drive components.
Coach and mentor Staff, Senior, and Junior mechanical engineers, improving technical rigor, design reviews, and professional development.
Occasionally travel or work nights, weekends, or on-call as required.