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Commonwealth Fusion Systems is seeking a Staff Dimensional Engineer to serve as the technical authority for dimensional management across HTS Magnet production and the SPARC fusion project. SPARC is a first-of-a-kind fusion machine presenting some of the hardest dimensional management challenges in industry: large high-field magnets, tight tolerances on complex geometries at meter scale, novel materials, and assembly stack-ups with no precedent.
In this role, you will define dimensional management discipline rather than inherit it. You will own how design intent becomes buildable, verifiable hardware by setting GD&T and datum strategy with Engineering, analyzing variation propagation through assembly sequences, and defining what gets measured and to what acceptance criteria. Your decisions will shape how fusion hardware is toleranced, measured, and accepted on SPARC and on the ARC power plants that follow.
Key responsibilities include:
- Set GD&T and datum strategy in partnership with Engineering, translating design intent into tolerancing that is functionally sound and manufacturable
- Perform tolerance stack-up and 3D variation analysis on large complex assemblies, predicting variation propagation through build sequences
- Architect inspection requirements for large metallic components and assemblies, defining what to measure, how, and acceptance criteria
- Drive key characteristic identification and flowdown from top-level assembly requirements to component and supplier drawings
- Support disposition of Non-Conformance Reports with dimensional analysis to inform use-as-is, rework, repair, or scrap decisions
- Review engineering change packages for dimensional impact as designs mature
- Coach QC Inspectors, Quality Engineers, and Design Engineers on GD&T interpretation and dimensional management practice
You will work alongside a metrology team equipped with laser trackers, portable CMM arms, and structured-light scanning, and with an established Quality Engineering organization.
REQUIREMENTS:
- BS in Mechanical, Industrial, Materials Science, Manufacturing, or Aerospace Engineering
- 10+ years of dimensional engineering experience on complex hardware (airframes, vehicle structures, turbomachinery, large equipment, or comparable)
- Mastery of GD&T (ASME Y14.5) as an author, not only an interpreter: datum strategy, tolerance allocation, and drawing review authority; GDTP certification strongly preferred
- Proven tolerance stack-up capability, both 1D (RSS, worst-case) and 3D variation analysis (3DCS, VisVA, or equivalent)
- Experience applying dimensional management to large assemblies: indexing strategies, key characteristics, and assembly sequence variation
- Demonstrated ability to translate design intent into inspection requirements and acceptance criteria
- Excellent communication and organization skills
- Ability to occasionally lift up to 50 lbs
- Willingness to travel or work required nights/weekends/on-call occasionally
- Ability to perform activities such as stooping, climbing, typing, standing, or sitting for extended periods
- Ability to work in a facility containing industrial hazards including heat, cold, noise, fumes, strong magnets, lead, high voltage, high current, pressure systems, and cryogenics
BONUS:
- Experience standing up dimensional management practices in a new program or organization (NPI, clean-sheet aircraft or vehicle programs)
- Working knowledge of SPC, process capability analysis, MSA/Gage R&R, and PFMEA
- Familiarity with metrology instruments applied to complex geometries (laser tracker, portable arms, CMM, structured light)
- Knowledge of NDE methods (PT, UT, ET, RT)
- Knowledge of cryogenics
- Minitab or JMP; MS Excel (including VBA); MS Visio
