Senior Modeling and Simulation Engineer

Commonwealth Fusion Systems•Milpitas, CA

About The Position

Commonwealth Fusion Systems is seeking a Senior Modeling and Simulation Engineer to join its design team and help build next-generation hardware for commercially viable fusion power plants. The role serves as a lead technical expert in advanced, predictive simulation of complex hardware systems, applying multiphysics modeling across thermal, structural, fluid-flow, and chemical regimes. The engineer will work in a collaborative, fast-paced environment to validate first-of-a-kind hardware, support design decisions, and optimize designs from concept through prototype deployment.

Requirements

Master’s or PhD degree in Mechanical Engineering, Aerospace Engineering, Physics, or a related field, with a strong focus on computational mechanics and multiphysics modeling.
At least 7 years of experience in simulation and predictive analysis of complex R&D systems.
Advanced, hands-on expertise with ANSYS, COMSOL Multiphysics, or equivalent high-end FEA/CFD simulation platforms.
Proven experience running coupled simulations, such as fluid-structure interaction, thermal-structural behavior, and chemical reaction modeling.
Ability to validate simulation results against physical test metrics such as strain-gauge data, thermal imaging, and flow sensors.
Ability to lift up to 25 lbs occasionally.
Ability to stoop, climb, stand, and sit for extended periods.
Willingness to travel or occasionally work nights, weekends, or on-call.
Commitment to safety and mitigation of industrial hazards, which may include heat, cold, noise, fumes, strong magnets, lead, high voltage, high current, pressure systems, and cryogenics.

Nice To Haves

Familiarity with applying industry codes to simulation-driven design validation.
Experience running transient dynamic simulations or modeling precision motion systems in extreme thermal environments.

Responsibilities

Execute advanced Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) for advanced processing equipment.
Build, run, and evaluate coupled simulations covering structural mechanics, high-temperature thermal management, fluid and gas flow dynamics, and chemical reaction kinetics.
Implement simulation data-management workflows, mesh-convergence criteria, and rigorous verification and validation protocols using physical test data.
Provide analytical leadership during technical design reviews, assessing structural margins, thermal stress distributions, and flow uniformity to guide design choices.
Collaborate with Mechanical Designers, Electrical Engineers, Materials Scientists, and Chemical Specialists to translate simulation insights into hardware modifications.
Own and report modeling milestones, timelines, and computational resources to stakeholders, ensuring on-time and in-spec delivery.
Resolve critical engineering bottlenecks and validate design-optimization paths from concept through prototype deployment.