{"id":2059261,"url":"https://alion.io/job/pacific-fusion-senior-mechanical-engineer-2","title":"Senior Mechanical Engineer","company":{"id":1933128,"name":"Pacific Fusion","domain":"pacificfusion.com","url":"https://alion.io/company/pacificfusion","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":{"grade":"A","score":87,"open_postings":23,"ghost_share":0.13,"stale_share":0,"repost_share":0,"time_to_fill_p50_days":78,"computed_at":"2026-10-30T05:48:23Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["San Leandro, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":138100,"max":263800,"currency":"USD","period":"year","gross":null,"usd_annual":263800},"salary_estimate":null,"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":true,"technologies":[{"name":"ANSYS","optional":false},{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-07-07T21:23:01Z","employer_posted_date":"2026-10-21","last_verified_at":"2026-10-31T01:56:39Z","board_verified":true,"closed_at":null,"days_open":115,"trust":{"level":"ok","repost_count":0,"flags":["company_stale"],"days_open":113},"description":"About Pacific Fusion\nPacific Fusion was founded in 2023 with the mission to power the world with abundant, affordable, clean energy.\nWe are rapidly designing and building a pulser-driven inertial fusion system to achieve net facility gain (more fusion energy output than stored energy input). In parallel, we are developing the key components required to build affordable fusion systems.\nOur plans are ambitious. We have raised over $900M so far from incredible investors, resourcing us to deliver on these plans. We are bringing together the best scientists, engineers, and operators from the fusion community, hard tech industry, and other sectors. We are united by a shared sense of urgency to provide clean power for the world, particularly managing climate change while meeting growing global energy demand. You can read more about us in this letter from our founders.\nWhy This Role Matters\nPacific Fusion is seeking an exceptional Senior Mechanical Engineer to help create the path to commercial fusion energy. You will help with the design, analysis, integration, and validation of mechanical systems and components across our advanced fusion energy platform. This role sits at the intersection of precision engineering and first-of-kind technology, demanding both deep technical expertise and the creative problem-solving mindset needed to tackle challenges no one has solved before. You will lead collaborative projects, mentor junior engineers, and play a vital role in driving our overall development effort.\nWhat You'll Do\nOwn assigned mechanical scope end-to-end, providing technical direction to multidisciplinary teams to translate system requirements into robust, deliverable designs\nProvide subject matter expertise in mechanical design and analysis for advanced diagnostic instrumentation, from concept through release\nDevelop precision motion and thermal management solutions compatible with high-vacuum and radiation environments\nDefine and verify mechanical alignment requirements for optical and detector systems, coordinating with metrology and assembly teams\nApply optomechanical design principles for mirrors, lenses, and optical mounts to ensure precision alignment and performance of diagnostic systems\nCreate and maintain 3D CAD models and 2D fabrication drawings with GD&T for machined, sheet-metal, and additive-manufactured components\nPerform FEA (structural, thermal) to validate designs against shock, vibration, and thermal loads expected in pulsed fusion experiments\nDrive hardware from prototype through delivery, installation, and commissioning, working with vendors and in-house shops in a rapid-turn laboratory setting\nMaintain rigorous revision control and configuration management in PDM/PLM systems: part numbering, BOMs, ECOs, and CAD library maintenance\nMentor early-career engineers and contribute to the technical development of the broader team\nPerform other duties as assigned\nWhat You Bring\nBachelor’s degree in mechanical engineering or related field; advanced degree a plus\nStrong first-principles engineering instincts and problem-solving skills\n5+ years’ experience in mechanical design for vacuum-compatible instrumentation, ideally with radiation or high-energy diagnostics\nExpert proficiency in a professional 3D CAD platform (Creo, NX, or SolidWorks), GD&T, and producing detailed manufacturing drawings\nSignificant experience with FEA tools (ANSYS, COMSOL) for structural and thermal analysis\nDemonstrated ability to navigate competing design constraints simultaneously: vacuum compatibility, radiation tolerance, thermal management, and tight geometric envelopes internally and between neighboring subsystems \nProven ability to operate as an effective individual contributor: self-directed and accountable for assigned deliverables end-to-end\nComfortable driving cross-functional stakeholders - vendors, technicians, and peer engineers - to keep mechanical deliverables on schedule\nExcellent verbal and written communication skills for technical documentation and cross-functional collaboration\nAble to work closely with team members and project manager in fast-paced environment with ambitious deadlines\nBonus Points\nExperience in fusion, plasma physics, accelerator physics, defense, or other high-consequence technical environments.\nFamiliarity with vacuum systems, cryogenics, high-voltage hardware, or pulsed power components.\nExposure to large-scale structural systems, pressure vessels, or custom capital equipment.\nPay Range:\n$138,100—$263,800 USD\nTOTAL COMPENSATION AND BENEFITS FOR ELIGIBLE EMPLOYEES\nIndustry-competitive salary\n\nEquity plan\n\n6% employer 401k matching\n\nGenerous paid time off (including sick leave, vacation, paid family leave)\n\nMedical, Dental, and Vision insurance\n\nActual base salary offered will be determined by: experience, skills, and work location. This range is for base salary, our total compensation includes equity and benefits. We welcome you to apply even if your expectations are outside our listed range. \nEQUAL OPPORTUNTITY\nPacific Fusion is committed to creating a diverse environment and is proud to be an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, or veteran status.\nPacific Fusion is committed to providing reasonable accommodations for qualified individuals with disabilities in our job application procedures and throughout employment. If you need assistance or any accommodation, please let us know. \nU.S. EXPORT CONTROL COMPLIANCE\nThis position may require access to information or technology that is subject to U.S. export control laws, such as ITAR or EAR. Under these regulations, we are required to ensure that such access is provided only to individuals who are classified as 'U.S. Persons.'This status includes U.S. citizens, U.S. nationals, lawful permanent residents (green card holders), and asylees and refugees with such status granted, not pending.\n\nRECRUITING AGENCIES\nPacific Fusion does not accept unsolicited resumes from recruiters or employment agencies without a fully executed recruitment agreement in place. In the absence of such agreement, Pacific Fusion reserves the right to pursue and hire any candidates without an obligation to pay fees. 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