Staff Dimensional Engineer – SPARC

Commonwealth Fusion Systems•Devens, MA

10d•Onsite

About The Position

Commonwealth Fusion Systems (CFS) is seeking a Staff Dimensional Engineer to be the technical authority for dimensional management across High-Temperature Superconducting (HTS) Magnet production and the SPARC project. This role involves defining how design intent becomes buildable, verifiable hardware by setting Geometric Dimensioning and Tolerancing (GD&T) and datum strategy with Engineering, analyzing variation propagation through assembly sequences, and defining measurement criteria. The decisions made will shape how fusion hardware is toleranced, measured, and accepted for SPARC and future ARC power plants. The engineer will collaborate with a metrology team and an established Quality Engineering organization.

Requirements

BS in Mechanical, Industrial, Materials Science, Manufacturing, or Aerospace Engineering
10+ years of dimensional engineering experience on complex hardware (airframes, vehicle structures, turbomachinery, large equipment, or comparable)
Mastery of GD&T (ASME Y14.5) as an author, not only an interpreter: datum strategy, tolerance allocation, and drawing review authority
Proven tolerance stack-up capability, both 1D (RSS, worst-case) and 3D variation analysis (3DCS, VisVA, or equivalent)
Experience applying dimensional management to large assemblies: indexing strategies, key characteristics, and assembly sequence variation
Demonstrated ability to translate design intent into inspection requirements and acceptance criteria
Excellent communication and organization skills
Ability to occasionally lift up to 50 lbs
Willingness to travel or work required nights/weekends/on-call occasionally
Perform activities such as stooping, climbing, typing, standing, or sitting for extended periods of time
Work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics

Nice To Haves

GDTP certification strongly preferred
Experience standing up dimensional management practices in a new program or organization (NPI, clean-sheet aircraft or vehicle programs)
Working knowledge of SPC, process capability analysis, MSA/Gage R&R, and PFMEA
Familiarity with metrology instruments applied to complex geometries (laser tracker, portable arms, CMM, structured light)
Knowledge of NDE methods (PT, UT, ET, RT)
Knowledge of cryogenics
Minitab or JMP; MS Excel (including VBA); MS Visio

Responsibilities

Set GD&T and datum strategy in partnership with Engineering, translating design intent into tolerancing that is functionally sound and manufacturable with our equipment and fabrication methods
Perform tolerance stack-up and 3D variation analysis on large complex assemblies, predicting variation propagation through build sequences and informing tooling, indexing, and assembly strategy
Architect inspection requirements for large metallic components and assemblies, defining what to measure, how, and to what acceptance criteria
Drive key characteristic identification and flowdown from top-level assembly requirements to component drawings and supplier requirements
Support disposition of Non-Conformance Reports with dimensional analysis, quantifying the assembly-level impact of as-built deviations to inform use-as-is, rework, repair, or scrap decisions
Review engineering change packages for dimensional impact as designs mature through SPARC assembly and integration
Coach QC Inspectors, Quality Engineers, and Design Engineers on GD&T interpretation and dimensional management practice