Sr Mechanical Engineer (Vacuum Systems)

Avalanche • Seattle, WA

7d • Onsite

About The Position

Avalanche Energy is seeking a Mechanical Engineer to design, build, and maintain mechanical systems supporting compact fusion devices. The role works directly on vacuum hardware, structural assemblies, thermal management systems, and supporting laboratory infrastructure, contributing to experiments that are designed, built, and iterated rapidly.

This is a deeply hands-on, lab-centered engineering role. Responsibilities span CAD modeling and component selection through fabrication, assembly, testing, and troubleshooting. The work includes precision vacuum systems, structural design, thermal and high-voltage management, and integration with experimental hardware, using materials ranging from stainless steels to refractory metals and ceramics. The position focuses on making complex mechanical systems work reliably and repeatably rather than on simulation-first or desk-based work.

The preferred location is onsite at either Tukwila or Richland, Washington, to support laboratory work and integration with experimental teams. Occasional travel may be needed for equipment procurement, integration, or collaboration. The schedule is standard business hours, with flexibility during experimental campaigns or critical test periods. Access to export-controlled information may be required; applicants must qualify as a U.S. person under U.S. trade control laws.

Requirements

• B.S. degree or higher in mechanical engineering, aerospace engineering, or a closely related field.
• 2–5 years of post-degree experience in hands-on mechanical engineering roles, preferably in a laboratory or experimental hardware environment.
• Strong command of mechanical engineering fundamentals, including structural analysis, thermal systems, fluid mechanics, and materials selection.
• Proficiency in 3D CAD tools such as SolidWorks, CATIA, or equivalent for design, assembly modeling, and drawing generation.
• Experience designing, assembling, and operating vacuum systems, including familiarity with pumping systems, gauging, and leak checking.
• Experience with thermal management design, including heat transfer analysis, cooling system design, and thermal interface materials.
• Experience working with machine shops and fabrication processes, including tolerance specification, GD&T, and hands-on assembly of precision mechanical hardware.
• Familiarity with FEA tools for structural or thermal analysis, such as ANSYS, Abaqus, or equivalent.
• Comfort working directly with physical hardware in a laboratory or machine shop environment, including hands-on assembly, installation, and testing.
• Applicants who may need access to export-controlled information must qualify as a U.S. person under U.S. trade control laws.

Nice To Haves

• Experience designing or building hardware for laboratory experiments, research programs, or scientific instruments.
• Experience working with ceramic materials, including MACOR or Alumina, in design or fabrication.
• Experience with high-vacuum or ultra-high-vacuum systems, including system design, bakeout, and troubleshooting.
• Familiarity with plasma physics hardware or fusion-related systems, such as magnetic coils, ion sources, beam optics, or high-voltage electrical feedthroughs.
• Experience with precision machining or direct hands-on fabrication, including lathe, mill, or other shop equipment.
• Experience working with cryogenic systems, high-pressure hardware, or other mechanically demanding environments.

Responsibilities

• Design, build, and maintain mechanical and vacuum systems supporting fusion experiments, diagnostics, and laboratory infrastructure.
• Work alongside physicists and engineers to conceive, implement, and refine mechanical systems for experimental hardware, from initial concept through fabrication, assembly, and iteration.
• Specify, procure, fabricate, and test mechanical hardware, including vacuum vessels, structural mounts, thermal interfaces, feedthroughs, and precision mechanical assemblies.
• Troubleshoot mechanical and vacuum systems hands-on, diagnosing issues related to leaks, thermal performance, structural loading, alignment, and hardware fit-up.
• Support experiment operation by setting up, validating, and maintaining mechanical systems, vacuum hardware, and associated diagnostics.
• Provide mechanical insight into experimental results, helping interpret hardware performance, system behavior, and failure modes.
• Contribute to continuous improvement of laboratory mechanical practices, documentation, fabrication standards, and build processes.

Benefits

• Excellent medical, dental, and vision benefits; the company pays 100% of premiums.
• 10 paid holidays and a company-wide December holiday break.
• Generous paid vacation and sick time.
• Weekly employer-provided team meals, a well-stocked kitchen, and employee events on and off-site.
• Opportunity for equity in the form of stock options.
• Exposure to a wide variety of challenging, hands-on engineering problems and professional growth.
• Small, tight-knit team with low barriers to action.

What This Job Offers

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