Staff Modeling and Simulation Engineer

Commonwealth Fusion Systems•Milpitas, CA

4d•$130,000 - $200,000•Onsite

About The Position

Commonwealth Fusion Systems (CFS) is seeking a Staff Modeling and Simulation Engineer to join their design team and contribute to the development of next-generation hardware. This role involves serving as a lead technical expert in advanced simulations, focusing on the predictive validation of complex hardware systems. The ideal candidate will be a highly skilled practitioner in multi-physics simulation, capable of modeling intricate interactions across thermal, structural, fluid flow, and chemical regimes. This position offers an opportunity to solve complex physics problems, apply rigorous modeling standards, and work in a dynamic, collaborative environment to deliver innovative hardware.

Requirements

Masterâ€™s or PhD degree in Mechanical Engineering, Aerospace Engineering, Physics, or a related field with a heavy focus on computational mechanics and multi-physics modeling.
10+ years of experience in simulation and predictive analysis of complex R&D systems.
Advanced, hands-on expert in ANSYS, COMSOL Multi-physics, or equivalent high-end FEA/CFD simulation platforms.
Proven track record of successfully running coupled simulations (e.g., fluid-structure interaction, thermal-structural behavior, and chemical reaction modeling).
Ability to bridge the gap between virtual models and the shop floor by validating simulation results against physical test metrics like strain gauge data, thermal imaging, and flow sensors.
Demonstrated ability to influence hardware design direction through analytical data and lead cross-functional initiatives in a matrixed environment.
Ability to lift up to 25 lbs occasionally.
Perform activities such as stooping, climbing, standing, sitting for extended periods of time.
Willingness to travel or work required nights/weekends/on-call occasionally.
Dedication to safety to mitigate industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics.
Compliance with U.S. laws concerning the export of controlled or protected technologies or information (collectively, â€œExport Control Laws").

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

Lead advanced Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) for advanced processing equipment.
Build, run, and evaluate highly coupled simulations covering structural mechanics, high-temperature thermal management, fluid/gas flow dynamics, and chemical reaction kinetics.
Implement engineering workflows for simulation data management, mesh convergence criteria, and rigorous verification and validation (V&V) protocols using physical test data.
Provide analytical leadership during technical design reviews, verifying structural margins, thermal stress distributions, and flow uniformity to guide design choices.
Partner closely with cross-functional teams, including Mechanical Designers, Electrical Engineers, Materials Scientists, and Chemical Specialists, to translate simulation insights into actionable hardware modifications.
Own and report on modeling milestones, timelines, and computational resources to stakeholders, ensuring on-time and in-spec delivery.
Coach and mentor junior engineering staff on modeling methodologies, simulation accuracy, and the practical application of finite element principles to real-world hardware.
Act with speed to solve critical engineering bottlenecks, validating design optimization paths from concept through prototype deployment.