{"id":1290239,"url":"https://alion.io/job/pacific-fusion-senior-mechanical-engineer-test-infrastructure","title":"Senior Mechanical Engineer - Test Infrastructure","company":{"id":1933128,"name":"Pacific Fusion","domain":"pacificfusion.com","url":"https://alion.io/company/pacificfusion","size_band":null,"is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":{"grade":"A","score":85,"open_postings":24,"ghost_share":0.167,"stale_share":0,"repost_share":0,"time_to_fill_p50_days":78,"computed_at":"2026-10-24T06:02:35Z"}},"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":150000,"max":219900,"currency":"USD","period":"year","gross":null,"usd_annual":219900},"salary_estimate":null,"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":true,"technologies":[{"name":"Abaqus","optional":true},{"name":"ANSYS","optional":true},{"name":"SolidWorks","optional":true}],"status":"live","first_seen_at":"2026-08-25T21:16:34Z","employer_posted_date":"2026-10-09","last_verified_at":"2026-10-24T20:17:50Z","board_verified":true,"closed_at":null,"days_open":60,"trust":{"level":"ok","repost_count":0,"flags":["company_stale"],"days_open":59},"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 a Senior Mechanical Engineer to lead the mechanical design, structural analysis, and physical implementation of core components and assemblies for our nuclear fusion demonstration system. In this role, you will take ownership of complex hardware from concept through detailed 3D CAD modeling, rigorous structural analysis, and final system integration. Working closely with physics, systems engineering, and manufacturing teams, you will tackle high-impact, high-precision engineering challenges to turn physics requirements into robust, high-performance hardware.\nWhat You'll Do\nLead the end-to-end mechanical design, 3D CAD modeling, and detail engineering of complex high-performance components and assemblies.\nPerform hand calculations, first-principles mechanical design, and advanced finite element analysis.\nTranslate high-level physics requirements, spatial constraints, and boundary conditions into robust engineering models and hardware specifications.\nConduct detailed tolerance stack-up analyses and impact assessments on part variances to ensure strict design interface requirements are met.\nApply Design for Manufacturability (DFM) and Design for Assembly (DFA) best practices to optimize performance, weight, cost, and lead times.\nInterface with cross-functional teams (physics, system integration, manufacturing) to resolve complex design trade-offs and mitigate technical risk.\nPrepare and maintain comprehensive engineering documentation, including fully dimensioned detail drawings (GD&T), and design review packages.\nWhat You Bring\nBachelor’s Degree in Mechanical Engineering required; Master’s or PhD is a plus.\n5+ years of hands-on experience in mechanical design and structural/thermal analysis for complex hardware systems.\nAdvanced proficiency in 3D CAD modeling software (e.g., Creo, SolidWorks).\nExtensive practical experience applying Finite Element Analysis software (e.g., ANSYS, Abaqus, or Creo Simulate) to evaluate stress, fatigue, thermal effects, and structural integrity.\nDeep understanding of GD&T (ASME Y14.5), tolerance stack-up analysis, and material selection for demanding environments.\nStrong knowledge of advanced manufacturing techniques (machining, additive manufacturing, precision welding) and DFM/DFA principles.\nStrong problem-solving capabilities with a solid foundation in engineering fundamentals.\nExcellent written and verbal communication skills, with a track record of cross-functional technical leadership.\nPay Range:\n$150,000—$219,900 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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