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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.
In this role, you will lead the full lifecycle of custom tooling, fixtures, and jigs for manufacturing and testing. You'll design and manage large, heavy-duty equipment including lifting rigs, spreader bars, turn-over fixtures, and specialized handling systems for multi-ton hardware. Your responsibilities span structural and mechanical design, vendor management, fabrication oversight, and proof-load testing.
Key focus areas include:
- Defining structural, mechanical, interface, and safety requirements aligned with lifting and rigging safety standards
- Managing vendor and fabrication shop relationships for build, machining, and delivery of heavy tooling assemblies
- Driving Design-for-Manufacturability (DFM) and Design-for-Assembly (DFA) optimization for hardware interfaces
- Supporting development of assembly, installation, and integration sequences for complex nuclear and industrial hardware
- Establishing precise tooling requirements for positioning, joining, inspection, testing, and precision metrology alignment
- Developing detailed work instructions, lift plans, and operational procedures for heavy tooling setup and factory integration
- Identifying and resolving tooling-related safety, structural, and integration risks before final assembly
- Supporting prototype builds, first-of-a-kind hardware integration, and hands-on troubleshooting during operations
You will work cross-functionally with design, manufacturing, and rigging teams in a hands-on environment.
REQUIREMENTS:
- 8+ years of progressive experience in custom tooling design, mechanical engineering, heavy equipment design, or hardware integration
- Proven track record designing, building, and deploying large, heavy custom tooling, multi-ton fixtures, lift frames, or specialized assembly equipment
- Direct familiarity and hands-on exposure to rigging principles, heavy lifting practices, spreader bar design, crane operations, and load testing standards
- Expert knowledge of structural design, welded steel structures, stress analysis, GD&T, tolerance stack-up, and mechanical interfaces
- Expertise in 3D CAD modeling (NX preferred) and finite element analysis in COMSOL or Ansys for custom machined/welded structures
- Experience developing assembly and integration processes, DFM/DFA, and hands-on support for manufacturing and installation
- Experience with precision alignment, metrology tools (e.g., laser trackers), and large electro-mechanical hardware assembly
- Background in nuclear, aerospace, fusion, heavy equipment, shipbuilding, semiconductor, or other highly engineered hardware industries
- Strong interpersonal communication and cross-functional leadership skills
Note: The posting states it is not necessary to meet all skillsets and encourages candidates to explain why they would be a great fit.
