Electromechanical Engineer

About the role

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. We are looking for a Senior Electromechanical Engineer specializing in Web Handling in Reel-to-Reel (R2R) processes to lead the development of our core manufacturing infrastructure. This is a high-impact role where you will be responsible for the architectural design of the automated systems that process our proprietary superconducting magnets. You will act as the technical authority for web-handling and tension-control systems, guiding the transition from R&D prototypes to high-reliability industrial production lines.

Responsibilities

• Design the hardware and controls for bespoke reel to reel process machines, ensuring seamless integration between high-precision mechanical assemblies and complex control software
• Serve as the Subject Matter Expert (SME) for machine design enabling roll to roll tension control, web handling and steering, winding dynamics, and in-line process modules, providing technical guidance to the manufacturing and design teams
• Scope and design electromechanical equipment to handle fragile high temperature superconducting tape with zero-defect tolerance
• Manage external vendors and integrators for the fabrication of large-scale equipment, ensuring adherence to Thea Energy’s rigorous performance and safety standards
• Design and implement advanced in-line inspection systems (e.g., computer vision, laser interferometry) to capture high-fidelity process data during continuous manufacturing
• Develop long-term strategies for manufacturing throughput, identifying bottlenecks in the R2R process and implementing automated solutions to increase yield and reliability

Requirements

• BS, MS, or PhD in Mechatronics, Mechanical Engineering, Electrical Engineering, or related fields
• 8+ years of experience in the electromechanical design and commissioning of complex reel-to-reel equipment, preferably in delicate material applications (e.g., semiconductor, battery electrode, or specialized aerospace)
• Expertise with Beckhoff/TwinCAT 3, EtherCAT, and structured text programming
• Experience with "Taper Tension" and specialized winding algorithms is highly desired
• Expertise in 3D CAD (NX preferred) and the use of FEA or multibody dynamics simulation to validate machine designs
• Ability to solve "first-of-a-kind" engineering challenges where no off-the-shelf solution exists