R&D Test Engineer

Commonwealth Fusion Systems•Devens, MA

1d•Onsite

About The Position

The R&D Test Engineer supports Commonwealth Fusion Systems’ mission by executing tests and projects across multiple disciplines and teams on aggressive schedules. The role focuses on testing and retiring risks for CFS high-temperature superconducting (HTS) magnets, particularly through the mechanical, electrical, and process design and construction of test equipment and supporting subsystems. The engineer designs, builds, and commissions equipment for development, qualification, and production testing, collaborating with manufacturing, R&D, procurement, and SPARC teams. The role also helps stakeholders reach agreement on why tests are needed and what data is essential to their objectives.

Requirements

Bachelor’s degree in an engineering or science field; mechanical engineering, electrical engineering, or a similar applied physics degree is specified.
At least 5 years of experience designing, building, and commissioning specialized test or industrial equipment, with hands-on experience and a demonstrated ability to deliver reliable data. A master’s degree with similar experience may be substituted.
At least 1 year of experience using CAD software to design electromechanical assemblies.
Proven understanding of mechanical loading, failure modes, material strength, fastener design, and bolted joints.
Understanding of mechanical engineering fundamentals for complex design maturation, including tolerancing, GD&T, form/fit/function, material selection, DFM, and DFA.
Solid grasp of electromagnetic fundamentals, including voltage, current, resistance, Ohm’s Law, AC/DC, the right-hand rule, and solenoids.
Proven troubleshooting and problem-solving skills, including the ability to develop creative solutions to challenging problems.
Proven collaboration skills, including active listening and facilitating productive discussion.
Exceptional written and verbal communication skills.
High self-motivation, drive to execute quickly, a can-do attitude, and eagerness to learn.
Ability to occasionally lift up to 50 pounds.
Ability to stoop, climb, type, stand, or sit for extended periods.
Dedication to safety in mitigating industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead, high voltage, and cryogenics.
Ability to work in industrial or loud environments while wearing proper PPE.
Willingness to travel or occasionally work required nights, weekends, or on-call.

Nice To Haves

Experience with structural FEA software, especially ANSYS and COMSOL, bolt-loading calculations, and failure criteria.
Experience using NX and Teamcenter.
Experience with traditional or superconducting high-field magnet testing.
Experience with weld design and stress analysis.
Experience commissioning new test facilities.
Experience designing fluid systems, including P&IDs, component selection, and ASME design codes.
Experience developing and executing complex test procedures involving multiple skill sets, testing phases, and third parties.
Familiarity with superconducting magnets, including Lorentz loads, magnet design, and conductor design.
Experience designing and using cryogenic equipment for liquid nitrogen and supercritical helium, including vacuum-jacketed equipment, cryocoolers, phase separators, and cold traps.
Experience designing and using high-vacuum equipment, including roughing pumps, turbopumps, ion gauges, and residual gas analyzers.
Experience designing and using high-voltage and high-current power equipment, including power supplies, water-cooled cables, and insulation.

Responsibilities

Own and retire technical risks by designing, analyzing, procuring, building, and commissioning test equipment.
Understand, challenge, and maintain well-documented requirements and risks for systems or components under test.
Develop test plans to retire technical risks, including defining instrumentation and controls for repeatable, reliable data.
Identify and mitigate safety hazards associated with test equipment and test plans; design safety into systems and prepare safety documentation such as job hazard assessments.
Prepare and lead Test Readiness Reviews before testing to ensure test activities are necessary and safe.
Design experiment campaigns suited to fast-paced schedules and work to maintain the proposed schedule.
Troubleshoot and resolve integration and test discrepancies during build, commissioning, and operation.
Improve test efficiency by iterating on designs, equipment, and operations for repeat tests.
Create first-principles analytical models to predict test results.
Compile test results clearly and communicate technical topics effectively to technical and nontechnical audiences.
Collaborate across manufacturing, R&D, procurement, and SPARC teams and help stakeholders agree on test objectives and essential data.