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Thea Energy is commercializing fusion energy using breakthroughs in stellarator physics and engineering. The company is reinventing the stellarator with computer-controlled arrays of planar coils, replacing complex modular magnets in traditional designs. This role is a senior manufacturing engineering position focused on scaling high-temperature superconductor (HTS) magnet production from prototype to full-scale manufacturing.
You will lead the development and standardization of manufacturing documentation for HTS magnets, including complex assembly procedures, work instructions, and rigorous quality inspection criteria. You own the end-to-end design, procurement, build, and commissioning of custom magnet manufacturing tooling, fixtures, and automated assembly equipment. You serve as the primary manufacturing liaison to the Magnet Engineering team, driving design for manufacturability, process FMEAs, and iterative design improvements from prototype to production.
You will architect and manage manufacturing BOMs, routings, and inventory workflows within PLM and MRP systems to ensure seamless execution. You author technical specifications, evaluate supplier capabilities, and partner with key vendors to procure high-precision hardware and capital equipment. You define technician roles, establish training programs, and mentor junior engineers and technical staff. You track, report, and take ownership of manufacturing milestones, schedule adherence, and budget constraints across primary magnet initiatives.
This is a hands-on role requiring deep expertise in advanced manufacturing processes and the ability to scale complex electro-mechanical assemblies into production. You will work at the intersection of cutting-edge physics and practical manufacturing engineering.
REQUIREMENTS:
- Bachelor's degree in Mechanical, Manufacturing, Aerospace, or Electrical Engineering (or related field)
- 7+ years of hands-on manufacturing engineering experience
- Extensive experience building complex electro-mechanical assemblies and introducing first-of-a-kind hardware processes into full-scale production
- Proven background in advanced joining and metal fusion processes, including high-precision soldering, brazing, electron beam, or TIG welding
- Demonstrated success scaling low-volume development projects into continuous production environments utilizing PLM, MRP, and ERP software platforms
- Deep expertise in drafting and interpreting engineering drawings with comprehensive Geometric Dimensioning and Tolerancing (GD&T) per ASME Y14.5
- Experience in magnetic confinement fusion, aerospace, medical devices, defense, or high-reliability advanced manufacturing sectors preferred
- Strong analytical capabilities, proactive leadership, and excellent communication skills
- Ability to occasionally lift objects up to 50 lbs
