Senior Mechanical Engineer Jobot
Parsippany, NJ9 days ago
About Thea Energy:
Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.
Position Overview:
We are seeking a Lead HTS Magnet Systems Engineer to own the full lifecycle of our large-scale High-Temperature Superconducting (HTS) cabled magnet systems. You will bridge interdisciplinary electrical and mechanical domains, driving everything from early stage design trade studies and cable architectures (CICC stacked REBCO) to manufacturing, assembly, QA test and integration into the device.
Key Responsibilities:
- End-to-End Program Ownership: Lead system design reviews (CDR/PDR), subsystem qualification, site commissioning, and risk mitigation across multi-year fusion hardware projects.
- Cabled HTS Design: Specify and optimize high-current cabled HTS conductors, managing thermomechanical stresses, high-field Lorentz forces, and thermal quench propagation.
- Large-scale manufacturing: Specify and review designs in the 1-10m range and in the 10-100 Tonne range.
- Electro-Mechanical Integration: Direct coupling between high-current electrical power leads, quench detection systems, cryogenic cooling interfaces, and structural mechanical supports.
- Vendor & Lifecycle Management: Oversee technical deliverables for HTS tape/cable vendors, manufacturing facilities, and integration test platforms.
Core Competencies & Requirements:
Direct Experience (10 - 15 Years Required)
- Superconducting Systems: Proven track record design and delivery of high-field (10T+) HTS cabled magnets or low-temperature (LTS) Cable-in-Conduit Conductors (CICC) for fusion applications.
- Program Execution: Demonstrated ownership of major lifecycle milestones in complex megaprojects (e.g., W7x, JT60SA, KSTAR, ITER -scale setups, or commercial fusion ventures) with budget ownership $10M - $50M.
- Failure Analysis & Test Operations: Hands-on leadership of full-scale magnet testing, cryogenic qualification (4.2K–20K), and post-test forensics.
- Start-up experience: Has dealt with the demands of a fast-growing start-up.
- Large-scale magnet manufacturing experience: Demonstrated experience with dealing with the challenges of forgings, composite insulation, solder potting in the 1-10m length scale and aware of the challenges.
Domain Knowledge
- Applied Superconductivity: REBCO 2G-HTS tape mechanics, strain limitations, current distribution, AC losses, and tape-to-cable joint architecture.
- Multiphysics Engineering: FEA modeling coupling electromagnetic forces (Lorentz/Maxwell), structural stress analysis, thermal management, and fluid flow (gaseous/supercritical helium).
- Quench Protection & Diagnostics: Active and passive protection systems, voltage tap arrays, fiber-optic temperature sensors, and high-speed dump circuit interfaces.
- Strategic Risk Mitigation: Mastery of FMEA (Failure Mode and Effects Analysis) applied to cryogenic system failures, vacuum loss (loss of vacuum/L VAC), and runaway quench scenarios.
Technical & Leadership Skills
- Systems Engineering: CONOPS, requirements, Interface control documentation (ICD), requirements traceability, and cross-functional leadership spanning electrical and mechanical teams.
- Software Tools: Proficiency with ANSYS, COMSOL, OPERA, MATLAB/Simulink, or custom HTS electrodynamic modeling tools.
Education
- B.S., M.S., or Ph.D. in Electrical Engineering, Mechanical Engineering, Applied Physics, or Nuclear Engineering.
Company Benefits:
- Comprehensive health benefits (e.g. medical/dental/vision)
- Employee equity stock options
- 20 days PTO
$180,000 - $220,000 a year
It’s not necessary to meet all of the skillsets outlined above. Please feel free to send us a note and tell us why you would still be a great fit for this role or Thea Energy.
Diversity and Inclusion:
Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. By creating a diverse environment, we will bring new ideas and approaches to solving some of the world’s hardest (and most important) problems. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran’s status, or other characteristic protected by applicable laws and regulations.
We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.