Staff Quality Engineer - Advanced Metrology Integration

About the role

Commonwealth Fusion Systems 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.

Responsibilities

• Manufacturing-Driven GD&T Interpretation: Partner closely with Engineering to understand design intent and define more manufacturable GD&T requirements; 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 risk-informed leadership to design engineers in dispositioning Non-Conformance Reports (NCRs) across the full range of outcomes (use-as-is, rework, repair, scrap), grounded in structural integrity and functional requirements
• Process Stabilization: Regularly analyze manufacturing data using control charts and process capability studies to identify emerging process drift, 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

Requirements

• Minimum 10+ years of Quality Engineering experience in a manufacturing, assembly or equipment manufacturing environment, specifically focused on transitioning new products to production
• Demonstrated program-level ownership of dimensional management or quality strategy, not solely execution of inspection plans defined by others
• Proven experience architecting inspection systems and measurement strategies for complex hardware, including defining what to measure, how, and to what acceptance criteria
• GDT 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 9001-2015, Six Sigma, Statistical Process Control (SPC), Process Capability Analysis, PFMEA, Measurement System Analysis (MSA), APQP
• Knowledge of NDE (non-destructive evaluation) methods including dye penetrant, ultrasonic, eddy current, and x-ray (Preferred)
• Knowledge of cryogenics (Preferred)
• Minitab or JMP, MS Excel (including VBA), MS Visio
• Excellent communication and organization skills

Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Science, Physics, or related field
• Experience with statistical tools such as Minitab or JMP for conducting Process Capability Analysis and Six Sigma methodologies
• 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

Benefits

• 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

Pay

$130,000 - $200,000 a year

Schedule

Full-time

Location

Devens, MA