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Thea Energy is commercializing fusion energy using stellarator physics and computer-controlled planar coil arrays. We are seeking an experienced Electromechanical Engineer to design and optimize our reel-to-reel manufacturing systems for high-temperature superconducting tape production.
You will serve as the Subject Matter Expert for machine design, responsible for creating bespoke reel-to-reel process machines that seamlessly integrate high-precision mechanical assemblies with complex control software. Your scope includes designing electromechanical equipment capable of handling fragile superconducting materials with zero-defect tolerance, managing external vendors and integrators for large-scale equipment fabrication, and ensuring adherence to rigorous performance and safety standards.
Key responsibilities include:
- Design hardware and controls for reel-to-reel process machines with seamless mechanical-software integration
- Provide technical guidance on roll-to-roll tension control, web handling, steering, winding dynamics, and in-line process modules
- Scope and design equipment for fragile high-temperature superconducting tape handling with zero-defect tolerance
- Manage external vendors and integrators for large-scale equipment fabrication
- Design and implement advanced in-line inspection systems (computer vision, laser interferometry) for high-fidelity process data capture
- Develop long-term manufacturing strategies, identify process bottlenecks, and implement automated solutions to increase yield and reliability
You will tackle first-of-a-kind engineering challenges where off-the-shelf solutions do not exist, working at the intersection of advanced materials, precision manufacturing, and control systems.
REQUIREMENTS:
- BS, MS, or PhD in Mechatronics, Mechanical Engineering, Electrical Engineering, or related fields
- 8+ years of experience in electromechanical design and commissioning of complex reel-to-reel equipment, preferably in delicate material applications (semiconductor, battery electrode, or specialized aerospace)
- Expertise with Beckhoff/TwinCAT 3, EtherCAT, and structured text programming
- Experience with Taper Tension and specialized winding algorithms (highly desired)
- Expertise in 3D CAD (NX preferred) and FEA or multibody dynamics simulation for machine design validation
- Ability to solve first-of-a-kind engineering challenges
Note: You do not need to meet all skillsets listed above; candidates are encouraged to explain why they would be a strong fit.
