{"id":2548907,"url":"https://alion.io/job/commonwealth-fusion-systems-principal-mechanical-engineer-web-handling","title":"Principal Mechanical Engineer - Web Handling","company":{"id":8705,"name":"Commonwealth Fusion Systems","domain":"cfs.energy","url":"https://alion.io/company/commonwealth-fusion-systems","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Lever","truth_index":{"grade":"A","score":85,"open_postings":5,"ghost_share":0,"stale_share":0.6,"repost_share":0,"time_to_fill_p50_days":54,"computed_at":"2026-11-01T06:10:25Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"lead","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Milpitas, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":187000,"max":270000,"currency":"USD","period":"year","gross":null,"usd_annual":270000},"salary_estimate":null,"experience_years_min":15,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"SolidWorks","optional":true}],"status":"live","first_seen_at":"2026-10-14T16:00:00Z","employer_posted_date":"2026-10-14","last_verified_at":"2026-11-01T22:56:49Z","board_verified":true,"closed_at":null,"days_open":18,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":18},"description":"Join the power movement as Principal Mechanical Engineer - Web Handling\nWe are looking for a Principal Mechanical Engineer specializing in Web Handling and Roll-to-Roll (R2R) systems to serve as the definitive company-wide technical authority for continuous material processing equipment. In this \"First Chair\" leadership role, you will shape the overall technical direction, architecture, and deployment of high-precision web transport systems operating in a variety of thermal environments.\nYou will lead the execution of highly complex, ambiguous cross-functional initiatives that directly impact our core R&D and manufacturing roadmap. Operating with complete independence, you will combine deep technical expertise in web dynamics and precision mechatronics, with strategic leadership establishing division-wide design standards, mitigating significant technical risks, and mentoring the engineering organization.\nWhat you'll do:\nShape R2R System Architecture: Serve as the chief architect for next-generation roll-to-roll equipment, dynamic tension systems, precision accumulators, and high-speed winders/unwinders\nResearch Advanced Winding & Unwinding Technologies: Actively research, evaluate, and benchmark next-generation web handling, winding, and unwinding equipment and technologies to inform tool architecture and roadmap decisions\nLead Cross-Functional Strategy: Translate complex scientific R&D objectives into actionable engineering architectures, bridging mechanical design, process physics, electrical hardware, and closed-loop controls across multiple project groups\n Master Web Dynamics & Technical Risk: Drive advanced dynamic modeling, web physics analysis, and experimental validation to resolve critical web defects (e.g., thermal buckling, lateral drift, scratching, or tension transients) in flexible metal substrates\nEstablish Division Standards: Institutionalize company-wide engineering standards, design guidelines, and testing methodologies for web handling, precision roller design, bearing selection, and mechatronics\nDrive Process & Tool Innovation: Pioneer novel mechanical concepts, dynamic guiding schemes, and non-contact web transport modules operating inside temperature zones\nIndependently Manage Risk: Identify, evaluate, and mitigate high-impact technical risks across major equipment initiatives, establishing contingency paths and robust design margins\nDirect Strategic Vendor Partnerships: Audit, qualify, and direct global suppliers and contract manufacturers for specialized R2R sub-assemblies, precision ground rollers, custom surface coatings, and drive components\nOrganization-Wide Mentorship: Actively coach and mentor Staff, Senior, and Junior mechanical engineers, elevating technical rigor, design review standards, and professional development across the discipline. \nWhat we’re looking for:\n Education: Master’s or PhD in Mechanical Engineering, Mechatronics, or a related field (or equivalent specialized industrial experience)\n Experience: 15+ years of proven track record as a recognized technical leader in the architectural design, scaling, and implementation of complex web handling, roll-to-roll (R2R), or converting equipment\nDeep Domain Expertise: 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\nCross-Disciplinary Mastery: Demonstrated capability to integrate mechanical systems seamlessly with advanced motion controls, power electronics, and thermal management systems\nProven Track Record in High-Stakes Tooling: Successful history of bringing first-of-a-kind continuous processing capital equipment from concept through commissioning and high-yield operational scale\nInfluential Leadership: Demonstrated ability to drive technical consensus and lead multi-disciplinary teams without relying on formal line management authority\nBonus points for:\n CAD & Simulation Leadership: 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\nBrittle & High-Strength Substrate Transport: Specialized experience handling narrow metal tapes, high-strength alloys, or delicate multi-layer composite webs\n Advanced Motion & Control Loops: Deep familiarity with tuning multi-axis servo drives, dancer control algorithms, and adaptive tension loops\nMust-have Requirements:\nAbility to occasionally lift up to 50 lbs\nPerform activities such as stooping, climbing, standing, or sitting for extended periods of time\nDedication to safety to mitigate industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, and cryogenics\nWillingness to travel or work required nights/weekends/on-call occasionally","description_format":"text","description_chars":4847,"description_truncated":false,"requirements":{"experience_years_min":15,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"master","optional":false},"security_clearance":false,"languages":[]},"benefits":["Professional development"],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Nuclear Energy","Nuclear Engineering"],"lifecycle":[{"event":"open","at":"2026-10-14T17:27:17Z"}],"visa":[],"liveness":{"score":90,"band":"hot","label":"Hiring now","p_open":1,"p_active":0.903,"p_room":1,"age_days":17,"expected_fill_days":54,"reasons":["conf:2","velocity","win:early","comp:brand"],"computed_at":"2026-11-01T06:10:25Z"},"pay":{"stated_usd_annual":270000,"is_top_pay":true},"html_url":"https://alion.io/job/commonwealth-fusion-systems-principal-mechanical-engineer-web-handling","json_url":"https://alion.io/job/commonwealth-fusion-systems-principal-mechanical-engineer-web-handling.json","meta":{"generated_at":"2026-11-02T01:30:19Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":2325,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-11-03T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":8705},"rest":"https://alion.io/mcp/rest/get_company?id=8705"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fcommonwealth-fusion-systems-principal-mechanical-engineer-web-handling"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fcommonwealth-fusion-systems-principal-mechanical-engineer-web-handling"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fcommonwealth-fusion-systems-principal-mechanical-engineer-web-handling"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/commonwealth-fusion-systems-principal-mechanical-engineer-web-handling\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fcommonwealth-fusion-systems-principal-mechanical-engineer-web-handling"}],"agent":{"mcp":"https://alion.io/mcp/jobs","mcp_open":"https://alion.io/mcp/open","next":[{"tool":"get_job","arguments":{"id":2548907}},{"tool":"search_jobs","arguments":{"company":"cfs.energy","detail":"compact"}},{"tool":"match_people","arguments":{"job_id":2548907},"note":"people open to offers who fit this vacancy"}],"note":"The same data through MCP tools: https://alion.io/mcp/open needs no sign-in (compact searches, postings, people); https://alion.io/mcp with an Alion account has everything. Docs: https://alion.io/developers"}}