Why This Role MattersPacific 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.
What You'll Do- 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.
What You Bring- 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.
Pay Range:
$138,100-$263,800 USD
Total Compensation & Benefits for Eligible Employees- 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
Actual base salary offered will be determined by: experience, skills, and work location. This range is for base salary, our total compensation includes equity and benefits. We welcome you to apply even if your expectations are outside our listed range.
