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Commonwealth Fusion Systems is seeking a Principal Mechanical Engineer specializing in Web Handling and Roll-to-Roll (R2R) systems to serve as the company-wide technical authority for continuous material processing equipment. This is a "First Chair" leadership role where you will shape the overall technical direction, architecture, and deployment of high-precision web transport systems operating in diverse thermal environments.
You will lead execution of highly complex, cross-functional initiatives that directly impact core R&D and manufacturing roadmaps. Operating with complete independence, you will combine deep technical expertise in web dynamics and precision mechatronics with strategic leadership to establish division-wide design standards, mitigate significant technical risks, and mentor the engineering organization.
Key responsibilities include:
- Serving as chief architect for next-generation roll-to-roll equipment, dynamic tension systems, precision accumulators, and high-speed winders/unwinders
- Actively researching, evaluating, and benchmarking next-generation web handling technologies to inform tool architecture and roadmap decisions
- Translating complex scientific R&D objectives into actionable engineering architectures, bridging mechanical design, process physics, electrical hardware, and closed-loop controls across multiple project groups
- Driving advanced dynamic modeling, web physics analysis, and experimental validation to resolve critical web defects (thermal buckling, lateral drift, scratching, tension transients) in flexible metal substrates
- Institutionalizing company-wide engineering standards, design guidelines, and testing methodologies for web handling, precision roller design, bearing selection, and mechatronics
- Pioneering novel mechanical concepts, dynamic guiding schemes, and non-contact web transport modules operating inside temperature zones
- Identifying, evaluating, and mitigating high-impact technical risks across major equipment initiatives
- Auditing, qualifying, and directing global suppliers and contract manufacturers for specialized R2R sub-assemblies, precision ground rollers, custom surface coatings, and drive components
- Actively coaching and mentoring Staff, Senior, and Junior mechanical engineers to elevate technical rigor and design review standards
Requirements:
- Master's or PhD in Mechanical Engineering, Mechatronics, or related field (or equivalent specialized industrial experience)
- 15+ years of proven track record as a recognized technical leader in architectural design, scaling, and implementation of complex web handling, roll-to-roll, or converting equipment
- Authoritative knowledge of web handling physics: closed-loop tension control, winder dynamics, lateral guiding, roller traction, nip mechanics, load cell integration, and substrate stress distribution
- Demonstrated capability to integrate mechanical systems seamlessly with advanced motion controls, power electronics, and thermal management systems
- Successful history of bringing first-of-a-kind continuous processing capital equipment from concept through commissioning and high-yield operational scale
- Demonstrated ability to drive technical consensus and lead multi-disciplinary teams without relying on formal line management authority
- Ability to occasionally lift up to 50 lbs and perform activities such as stooping, climbing, standing, or sitting for extended periods
- Dedication to safety to mitigate industrial hazards including heat, cold, noise, fumes, strong magnets, lead, high voltage, and cryogenics
- Willingness to travel or work required nights/weekends/on-call occasionally
Bonus qualifications:
- Advanced mastery of 3D CAD platforms (SolidWorks and/or NX) paired with expertise in multi-body dynamics, non-linear FEA, and finite-difference web simulations
- Specialized experience handling narrow metal tapes, high-strength alloys, or delicate multi-layer composite webs
- Deep familiarity with tuning multi-axis servo drives, dancer control algorithms, and adaptive tension loops
