Staff Mechanical Engineer, Vacuum Systems Job at Realta Fusion Inc. (Madison)

Job Description

The Staff Mechanical Engineer, Vacuum Systems will work closely with Realta’s engineering and scientific teams to provide technical leadership, engineering expertise, and critical design input that advances Realta’s technology development roadmap. This individual will play a key role in the design, development, and execution of Hammir—Realta’s reactor-scale simple magnetic mirror and primary technology development platform, and Realta’s first-of-a-kind fusion pilot plant. They will be expected to drive complex engineering initiatives, mentor junior engineers, and contribute to strategic decisions that support the commercialization of fusion energy.

Job Responsibility

Collaborate with both physicists and scientists, as well as engineers and technical support staff, to develop technologies for novel vacuum systems requiring innovative designs and critical high-level analysis
Design and model complex ultra-high vacuum (UHV) pumping technologies, diagnostics, in-situ high temperature bakeout, sealing strategies, and vacuum vessels
Establish UHV best practices, design vacuum cleaning and handling laboratories, and mentor staff in UHV principles, contamination control, and leak detection
Design, build, and operate UHV test stands to validate both established and emerging vacuum technologies against stringent performance requirements
Research, select, and occasionally test UHV-compatible materials (e.g., low-outgassing metals, specific elastomers/metals for seals), specify cleaning protocols, and define bakeout and pump down sequences
Lead efforts involving general mechanical-system design, mechanical stress analysis, thermal analysis, and fatigue analysis
Interface with facilities and assist in the specification, design, and construction of a greenfield cryoplant and associated gas delivery systems
Conduct formal design reviews, generate technical documentation, and respond to questions concerning engineering design and operation
Work with vendors and internal resources to fabricate, assemble, test, and validate components and systems
Communication: Synthesize and present technical work internally and externally, communicate daily with project teams and leadership to support programmatic needs
Safety: Contribute to the establishment of company safety standards and lead implementation of these standards within R&D and Engineering team
Culture and Values: Foster a positive and inclusive work environment that aligns with the company's mission, values, and sustainability goals, promoting innovation, collaboration, and employee engagement

Requirements

BS in Mechanical Engineering, Materials Science, Aerospace Engineering, or a related field, plus 8+ years’ work experience
Extensive experience and expertise in 3D CAD design with current CAD software tools (SolidWorks, NX, Creo, etc.) and familiar with PDM
Demonstrated understanding of pressure vessel design, structural analysis, heat transfer, and thermal analysis, and the ability to leverage FEA tools such as ANSYS or COMSOL to solve engineering problems
Deep expertise of vacuum pump technologies (ion, turbomolecular, scroll, diffusion, cryogenically cooled panels, getters, etc…) and sealing and bakeout techniques for large vacuum chambers
Highly proficient in vacuum conductance and pump down modelling and optimization using tools such as MolFlow, VacTran, hand calculations, or other
Substantial technical experience with advanced knowledge and judgement in most of the following areas: Design, commissioning, and operation of ultra-high vacuum systems and parts compatible with vacuum environments
Welding, machining, and mechanical assembly processes and techniques
Project management abilities defined as the ability to control scope, cost, and schedule
Metrology, inspection, quality control, and test methods related to manufacturing using CMMs, laser trackers, FARO arms, or other test equipment
Demonstrated ability to supervise and safely direct activities of small teams of technical personnel
Ability to interact and communicate efficiently with researchers, engineers, designers, machinists, and technicians to provide a high level of customer service
GD&T and P&ID proficiency within ASME standards
Collaboration: Exceptional interpersonal and communication skills (written, verbal, public presentation) to collaborate effectively with colleagues, external partners, and stakeholders

Nice to have

Master’s Degree or higher in Mechanical Engineering or related field
Professional Engineering (PE) license
Direct experience with cryogenic systems for ultra-high vacuum applications
Strong interest in exploring emerging vacuum technologies such as NEG, combination pumps, magnetic-field resistant gauges, and others
Experience in designing for and working within radiation environments
Experience with high-voltage systems, megawatt-scale heating and cooling systems, and specialty materials for fusion or particle accelerator applications
Experience with nuclear Commercial-Grade Dedication (CGD) or related standards

What we offer

Competitive compensation package, including equity stock options
Comprehensive benefits including health, dental, and vision insurance, plus a retirement savings plan
Flexible paid time off (PTO) to support work-life balance
Work and live in Madison, Wisconsin — one of America’s most livable and vibrant cities

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Staff Mechanical Engineer, Vacuum Systems

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