Senior Materials Engineer, Material Health Monitoring
About The Position
Helion is a fusion power company based in Everett, WA, with the mission to build the world's first fusion power plant, enabling a future with unlimited clean electricity. This role is for a Senior Materials Engineer to lead the development of materials health monitoring for Helion’s fusion generators. The engineer will design, qualify, and deploy in-situ and ex-situ diagnostics to detect and quantify materials degradation under combined stimuli, including thermomechanical stress, radiation, high electric fields, and coolant environments. This position involves cross-functional collaboration with Materials, Research, and Engineering teams to translate failure modes into measurable signals and integrate diagnostics into hardware and predictive models. The role reports to the Lead Materials Scientist and is an onsite position in Everett, WA.
Requirements
- BS with 10+ years, or MS/PhD with 5+ years, in Materials Science, Materials Engineering, Applied Physics, Nuclear Engineering, or related field
- 5+ years (with PhD or MS) or 10+ years (with BS) of experience in at least one of: Materials diagnostics / NDE / SHM (strain, acoustic, optical, EM, fiberoptic, etc.)
- Familiarity with data analysis / feature extraction for degradation detection (Python preferred)
- Experience designing and executing coupled-stimuli experiments (e.g., thermomechanical, electrothermal, irradiation with stress)
- Experience embedding or integrating sensors into structural materials (ceramics, composites, polymers, or metals)
Nice To Haves
- Experience in fusion, fission, accelerator, or high-radiation environments
- Experience with radiation effects and post-irradiation examination (PIE)
- Familiarity with high-voltage systems or safety-critical experimental environments
Responsibilities
- Develop and deploy in-situ and ex-situ diagnostics for degradation and failure in fusion-relevant materials and components (e.g., first wall, magnets, insulators, capacitors, HV interfaces, seals)
- Translate failure and degradation modes into measurable signals using sensors, inspection methods, or indirect indicators
- Design and execute coupled-stimuli experiments and post-irradiation examinations (PIE) to validate diagnostic methods
- Build test matrices and analysis plans linking microstructural evolution to sensor outputs and component performance
- Own the materials diagnostics roadmap by converting risk assessments into diagnostic requirements (what to measure, where, how often, and accuracy)
- Collaborate with design engineers to embed diagnostics into hardware and ensure compatibility with system constraints
- Partner with modeling teams to integrate diagnostic outputs into predictive models and maintenance strategies
- Productize diagnostic methods and sensors for reliable deployment in fusion environments
- Document test plans, procedures, and design guidance; communicate results, risks, and recommendations across teams
Benefits
- Medical, Dental, and Vision plans for employees and their families
- 31 Days of PTO (21 vacation days and 10 sick days)
- 10 Paid holidays, plus company-wide winter break
- Up to 5% employer 401(k) match
- Short term disability, long term disability, and life insurance
- Paid parental leave and support (up to 16 weeks)
- Annual wellness stipend
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What This Job Offers
Job Type
Full-time
Career Level
Senior
