{"id":3346500,"url":"https://alion.io/job/vulcan-elements-senior-design-engineer","title":"Senior Design Engineer","company":{"id":8041,"name":"Vulcan Elements","domain":"vulcanelements.com","url":"https://alion.io/company/vulcanelements","size_band":"51-200","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":{"grade":"A","score":91,"open_postings":6,"ghost_share":0,"stale_share":0.167,"repost_share":0,"time_to_fill_p50_days":71,"computed_at":"2026-11-01T06:10:25Z"}},"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":["Durham, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":86000,"max_usd":163000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":6333},"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Fusion 360","optional":false},{"name":"SolidWorks","optional":false}],"status":"live","first_seen_at":"2026-10-27T15:38:25Z","employer_posted_date":"2026-10-27","last_verified_at":"2026-11-02T01:07:54Z","board_verified":true,"closed_at":null,"days_open":5,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":5},"description":"Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive, powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Integrity.\nThe CAD Designer owns new designs for parts and equipment in our R&D and pilot facility, from initial measurements and concepts through fabrication drawings, assembly and as-built documentation.This role uses SolidWorks, Fusion 360 or similar CAD software to turn evolving process needs into practical, buildable parts and assemblies.The ideal candidate combines strong mechanical design skills with hands-on machining, building, welding, repair or similar experience, and works closely with engineers, technicians and fabricators to make designs work in practice.\nResponsibilities\nMechanical Design and Development\nDesign reactor parts, refractory geometry, cathodes, lids, and replacement components for high-temperature molten-salt electrochemical cells.\nDevelop powder-metal feed-system parts, including hoppers, feed chutes, interfaces and mechanisms.\nAdd features to machined components and design tooling, fixtures and equipment modifications for R&D and pilot projects.\nCreate parametric 3D models and assemblies; check fits, interference, clearances and access for installation and maintenance.\nWork with engineers to incorporate material compatibility, thermal expansion, electrical isolation and cooling requirements into reviewed designs.\nFabrication and Build Support\nDesign for available manufacturing methods and practical shop constraints, including:\nMachining access, achievable tolerances, standard stock sizes and inspection requirements.\nWeld access, assembly sequence, fasteners and serviceability.\nMeasure existing equipment and reverse-engineer worn or undocumented parts; verify critical dimensions before fabrication.\nWork directly with machinists, welders, suppliers and technicians to resolve build issues, check fit and improve designs after testing.\nDrawings and Spare Parts\nProduce fabrication-ready drawings with dimensions, tolerances, materials, finishes and applicable weld details.\nMaintain bills of materials, part numbers, CAD files and revision-controlled drawing packages.\nOwn spare-part drawings and update as-built records so replacement parts can be ordered and installed reliably.\nSupport supplier quotations and review proposed manufacturing changes with the responsible engineer.\nManage multiple design requests and communicate priorities, lead times and design changes to the project team.\nResponsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.\nQualifications\nTechnical training in CAD, drafting or mechanical design, or equivalent practical experience.\nDemonstrated experience designing mechanical parts and assemblies in SolidWorks, Fusion 360 or similar parametric CAD software.\nHands-on experience in machining, fabrication, welding, equipment assembly, repair or a similar trade.\nAbility to produce clear shop drawings and apply appropriate dimensions, tolerances and fits.\nAbility to use measuring tools and translate physical parts and equipment into accurate CAD models.\nUnderstanding of manufacturing constraints and how design choices affect cost, lead time and buildability.\nAbility to incorporate feedback from the shop floor and work through design changes in a fast-moving R&D environment.\nStrong attention to detail, organized documentation and clear communication with engineers, technicians and suppliers.\nMust be a U.S. Person due to required access to U.S. export-controlled information or facilities.\nPreferred Qualifications\nExperience with high-temperature equipment, materials selection at high temperature, or metals processing equipment.\nExperience with powder handling, press feed systems, tooling or precision-machined components.\nExperience with copper busbars or buspipes, cooled assemblies, weldments or refractory components.\nFamiliarity with GD&T, tolerance stack-ups, CAD data 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