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Avalanche Energy, a Washington-based fusion startup, is seeking a Senior Mechanical Engineer with deep expertise in vacuum systems to design, build, and maintain the vacuum and mechanical systems supporting compact, deployable fusion devices. This is a hands-on, lab-centered role focused on ultra-high-vacuum (UHV, <10⁻⁷ torr) hardware, structural assemblies, thermal management systems, and laboratory infrastructure.
You will work directly on all aspects of mechanical and vacuum system engineering: CAD modeling and component selection through fabrication, assembly, testing, and troubleshooting. Responsibilities include designing and building mechanical and vacuum systems for fusion experiments and diagnostics; specifying, procuring, fabricating, and testing vacuum vessels, structural mounts, thermal interfaces, feedthroughs, and precision assemblies; performing hands-on troubleshooting of leaks, thermal performance, structural loading, and alignment issues; supporting experiment operation by setting up and validating mechanical systems; providing mechanical insight into experimental results and failure modes; and contributing to continuous improvement of lab practices, documentation, and fabrication standards.
The role demands comfort moving fluidly between CAD modeling, design analysis, and hands-on assembly and troubleshooting in a machine shop and laboratory environment. You will work with materials ranging from stainless steels to refractory metals and ceramics, and collaborate closely with physicists and engineers to iterate rapidly on experimental hardware.
Avalanche is backed by U.S. government programs and focuses on near-term applications in fusion neutron production for radioisotope power and defense/space uses. The company values people energized by hands-on problem solving, real hardware delivery, and aggressive timelines.
Location is onsite in Tukwila or Richland, Washington, required to support hands-on laboratory work and close integration with experimental teams. Occasional travel for equipment procurement and collaboration. Standard business hours with flexibility during experimental campaigns.
REQUIREMENTS:
- B.S. degree or higher in mechanical engineering, aerospace engineering, or closely related field
- 8–12 years of post-degree experience in hands-on mechanical engineering roles with significant focus on vacuum systems, preferably in laboratory or experimental hardware environment
- Strong command of mechanical engineering fundamentals: structural analysis, thermal systems, fluid mechanics, materials selection
- Proficiency in 3D CAD tools (SolidWorks, CATIA, or equivalent) for design, assembly modeling, and drawing generation
- Experience designing, assembling, and operating vacuum systems, including pumping systems, gauging, and leak checking
- Experience with high-vacuum or ultra-high-vacuum (UHV) systems, including system design, bakeout, and troubleshooting
- Demonstrated expertise in UHV system design and best practices: material selection, surface preparation, cleaning protocols for UHV compatibility
- Experience establishing or improving vacuum standard operating procedures
- Deep familiarity with vacuum diagnostics and troubleshooting: residual gas analysis, virtual leak identification, outgassing source identification
- Experience with thermal management design: heat transfer analysis, cooling system design, thermal interface materials
- Experience working with machine shops and fabrication processes: tolerance specification, GD&T, hands-on assembly of precision hardware
- Comfort working directly with physical hardware in laboratory or machine shop environment: hands-on assembly, installation, test
DESIRED QUALIFICATIONS:
- Experience designing or building hardware for laboratory experiments, research programs, or scientific instruments
- Experience with ceramic materials design or fabrication (MACOR, Alumina)
- Familiarity with plasma physics hardware or fusion-related systems (magnetic coils, ion sources, beam optics, high-voltage feedthroughs)
- Experience with precision machining or direct hands-on fabrication (lathe, mill, shop equipment)
- Experience with cryogenic systems, high-pressure hardware, or other mechanically demanding environments
- Familiarity with FEA tools for structural or thermal analysis (ANSYS, Abaqus, or equivalent)
Note: This position may require access to export-controlled information. Applicants must be a "U.S. person" as defined by U.S. trade control laws (U.S. citizen, lawful permanent resident, or protected individual).
