Senior Mechanical Engineer

About the role

Lead the design and development of groundbreaking fusion technologies that will help power the future of clean energy. The Senior Mechanical Engineer 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‑DD, Realta’s reactor‑scale tandem magnetic mirror and development platform ahead of 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.

Responsibilities

• Develop 3D models and technical drawings for complex beamline and fusion device elements to be operated in ultra‑high vacuum environments.
• Manage the full engineering lifecycle from conception, construction, and field installation to operational deployment and beyond.
• Translate concepts into detailed engineering drawings, carry out design analysis, identify potential problems, and independently or collaboratively develop solutions.
• Lead efforts involving general mechanical‑system design, mechanical stress analysis, thermal analysis, and fatigue analysis.
• 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.
• Supply hands‑on support in fabrication and assembly of prototype and laboratory systems, up to and including operating machine shop equipment.
• 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.

Required Qualifications

• Education: BS in Mechanical Engineering, Nuclear Engineering, or a related field, plus 5‑8 years’ work experience.
• Extensive experience and expertise in 3D CAD design with current CAD software tools (SolidWorks, NX, Creo, etc.) and familiarity with PDM.
• Demonstrated understanding of mechanism design, structural analysis, heat transfer, and thermal analysis, with the ability to leverage FEA tools such as ANSYS or COMSOL.
• Technical experience with the installation and commissioning of precision scientific, mechanical, cryogenic, hydraulic, plumbing, and/or vacuum systems.
• 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.

Preferred Qualifications

• Master’s Degree or higher in Mechanical Engineering or related field.
• Professional Engineering (PE) license.
• Experience in designing for and working within radiation environments.
• Experience with cryogenic systems for ultra‑high vacuum applications.
• 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.

Compensation and Benefits

• 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.
• Commitment to diversity, inclusion, and equal employment opportunity.