R&D Test Engineer

Commonwealth Fusion Systems•Devens, MA

3d•$107,000 - $160,000•Onsite

About The Position

Commonwealth Fusion Systems is seeking an R&D Test Engineer to execute tests and projects on aggressive schedules in support of its fusion-energy mission. The engineer will test and retire risks for CFS high-temperature superconducting (HTS) magnets, with particular focus on the mechanical, electrical, and process design and construction of test equipment and supporting subsystems. The role requires a fundamental understanding of at least one engineering discipline: mechanical, electrical, or fluids. The engineer will design, build, and commission equipment for development, qualification, and production testing, collaborating with manufacturing, R&D, procurement, and SPARC teams. They will also help stakeholders reach agreement on the purpose of tests and the data needed to achieve their outcomes. The position covers test-equipment design and commissioning, requirements and risk management, test planning and execution, safety, troubleshooting, analytical modeling, and communication of test results. The role may involve industrial environments and occasional travel, nights, weekends, or on-call work. It is an onsite position and requires compliance with U.S. export control laws.

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.
Understanding of mechanical loading, failure modes, material strength, fastener design, and bolted joints.
Understanding of mechanical engineering fundamentals used in design maturation, including tolerancing, GD&T, form/fit/function, material selection, design for manufacturing (DFM), and design for assembly (DFA).
Solid grasp of electromagnetic fundamentals, including voltage, current, resistance, Ohm's Law, AC/DC, the right-hand rule, and solenoids.
Demonstrated troubleshooting and problem-solving skills, including the ability to devise creative solutions to challenging problems.
Demonstrated collaboration skills, including active listening and facilitating productive discussion of problems.
Exceptional written and verbal communication skills.
High self-motivation and drive to execute quickly, a can-do attitude, and eagerness to learn.
Ability to occasionally lift up to 50 pounds.
Ability to perform activities such as stooping, climbing, typing, standing, or sitting for extended periods.
Dedication to safety when mitigating industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, and cryogenics.
Ability to work in industrial or loud environments while using proper PPE.
Willingness to travel or work required nights, weekends, or on-call occasionally.
Ability to comply with U.S. export control laws concerning controlled or protected technologies or information; any employment offer is contingent on compliance.

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 or 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, particularly tests involving multiple skill sets, 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

Design, analyze, procure, build, and commission test equipment to own and retire technical risks, using knowledge of physics, structures, instrumentation and controls, and mechanical and electrical systems.
Understand, challenge, and maintain well-documented requirements and risks for systems or components under test.
Develop test plans that retire technical risks and define 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 (TRRs) before testing to confirm test activities are required and safe.
Design experiment campaigns suited to the fast pace and work to maintain proposed schedules.
Troubleshoot and resolve integration and test discrepancies during build, commissioning, and operation.
Improve designs, equipment, and operations to increase efficiency for repeat tests.
Create first-principles analytical models to predict test results.
Compile test results clearly for review and communicate technical topics to technical and nontechnical audiences.
Collaborate across manufacturing, R&D, procurement, and SPARC teams to execute test campaigns and establish test objectives and required data.