Join the power movement as Staff Quality Engineer - Advanced Metrology Integration

Commonwealth Fusion Systems (CFS) is seeking a Staff Quality Engineer to serve as the subject matter expert (SME) for dimensional management and quality strategy for our HTS Magnet production and the SPARC Project. In this high-impact role, you will be the technical authority on Geometric Dimensioning and Tolerancing (GD&T), ensuring that novel, first-of-a-kind designs are translated into manufacturable and verifiable hardware.

The Staff role will be the technical authority responsible for taking "good enough" prints and collaborating with Manufacturing Engineering to develop the inspection infrastructure, tooling, and process controls required to build them. You will serve as the expert in applying GD&T to real-world fabrication challenges, ensuring that the SPARC project meets its mission through pragmatic, risk-informed quality solutions.

What you'll do:

• Manufacturing-Driven GD&T Interpretation:
  • Take complex design requirements and work directly with Manufacturing Engineers to determine how to achieve critical tolerances using existing equipment and novel fabrication methods
• Proactive Problem Solving:
  • Lead the development of risk-informed QA controls that bridge the gap between design intent and shop-floor reality to positively impact the CFS mission
• Inspection Architecture:
  • Architect measurement systems and quality inspection methods specifically designed for the assembly of large metallic components, moving beyond theoretical models to executable floor-level plans
• Disposition Leadership:
  • Provide high-level leadership in dispositioning Non-Conformance Reports (NCRs), focusing on "use-as-is" or "rework" justifications based on structural integrity and functional requirements
• Process Stabilization:
  • Regularly analyze manufacturing data using control charts and process capability studies to identify where the "build" is diverging from the "print," escalating insights to Operations to drive immediate process adjustments
• Sub-system Integration:
  • Facilitate the creation and execution of PFMEAs and Quality Plans for the installation of sub-systems, ensuring that assembly tolerances are managed as the SPARC project scales
• Measurement System Analysis (MSA):
  • Lead advanced MSA and Gage R&R studies to ensure that the methods used to measure novel designs are statistically sound and repeatable in a production environment
• Mentorship & Oversight:
  • Provide technical coaching to QC Inspectors and Quality Engineers, specifically regarding GD&T interpretation on the shop floor

What we're looking for:

• BS in Mechanical, Industrial, Material Science or Manufacturing Engineering
• Minimum 10+ years of Quality Engineering experience in a manufacturing, assembly or equipment manufacturing environment, specifically focused on transitioning new products to production
• GD&T Expertise: Mastery of GD&T (ASME Y14.5) with a proven ability to translate theoretical tolerances into practical manufacturing work instructions
• Metrology: Deep knowledge of CMM, Romer Arm, and Laser tracker applied to complex geometries
• ISO [redacted], Six Sigma, Statistical Process Control (SPC), Process Capability Analysis, PFMEA, Measurement System Analysis (MSA), APQP
• GD&T and Metrology
• Knowledge of cryogenics
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• Minitab or JMP, MS Excel (including VBA), MS Visio
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• Excellent communication and organization skillsGD&T and Metrology Knowledge of NDE (non-destructive evaluation) methods including dye penetrant, ultrasonic, eddy current, and x-ray
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Bonus points for:

• Hardware Assembly: Extensive experience with the assembly of large metallic components, welding processes and Nondestructive Testing
• Statistical Tools: Proficiency in Minitab or JMP for conducting Process Capability Analysis and Six Sigma methodologies

Must-have Requirements:

• 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

$130,000 - $200,000 a year

Salary range for this full-time position + equity + benefits. The actual salary will depend on level, location, qualifications, and experience. The range displayed on each job posting reflects new hire salaries for the position across all US locations. Benefits include:

• Competitive compensation with equity

• 13 Company-wide Holidays

• Flexible vacation days

• 10 sick days

• Generous parental leave policy

• Health, dental, and vision insurance

• 401(k) with employer matching

• Professional growth opportunities

• Team-building activities

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