Senior Mechanical Engineer - Test Infrastructure

Pacific Fusion • San Leandro, CA

4d

About The Position

Pacific Fusion is seeking a Senior Mechanical Engineer to lead the mechanical design, structural analysis, and physical implementation of core components and assemblies for our nuclear fusion demonstration system. In this role, you will take ownership of complex hardware from concept through detailed 3D CAD modeling, rigorous structural analysis, and final system integration. Working closely with physics, systems engineering, and manufacturing teams, you will tackle high-impact, high-precision engineering challenges to turn physics requirements into robust, high-performance hardware.

Requirements

• Bachelor’s Degree in Mechanical Engineering required; Master’s or PhD is a plus.
• 5+ years of hands-on experience in mechanical design and structural/thermal analysis for complex hardware systems.
• Advanced proficiency in 3D CAD modeling software (e.g., Creo, SolidWorks).
• Extensive practical experience applying Finite Element Analysis software (e.g., ANSYS, Abaqus, or Creo Simulate) to evaluate stress, fatigue, thermal effects, and structural integrity.
• Deep understanding of GD&T (ASME Y14.5), tolerance stack-up analysis, and material selection for demanding environments.
• Strong knowledge of advanced manufacturing techniques (machining, additive manufacturing, precision welding) and DFM/DFA principles.
• Strong problem-solving capabilities with a solid foundation in engineering fundamentals.
• Excellent written and verbal communication skills, with a track record of cross-functional technical leadership.

Responsibilities

• Lead the end-to-end mechanical design, 3D CAD modeling, and detail engineering of complex high-performance components and assemblies.
• Perform hand calculations, first-principles mechanical design, and advanced finite element analysis.
• Translate high-level physics requirements, spatial constraints, and boundary conditions into robust engineering models and hardware specifications.
• Conduct detailed tolerance stack-up analyses and impact assessments on part variances to ensure strict design interface requirements are met.
• Apply Design for Manufacturability (DFM) and Design for Assembly (DFA) best practices to optimize performance, weight, cost, and lead times.
• Interface with cross-functional teams (physics, system integration, manufacturing) to resolve complex design trade-offs and mitigate technical risk.
• Prepare and maintain comprehensive engineering documentation, including fully dimensioned detail drawings (GD&T), and design review packages.

Benefits

• Industry-competitive salary
• Equity plan
• 6% employer 401k matching
• Generous paid time off (including sick leave, vacation, paid family leave)
• Medical, Dental, and Vision insurance

What This Job Offers

• Job Type: Full-time
• Career Level: Senior