Electronics Hardware Design Engineer

Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.

Thea Energy is seeking a highly skilled Electronics Hardware Design Engineer to lead the design and development of electronics, power electronics, and embedded control hardware for the Power Supply Systems, and Data Acquisition Units for the Control System of the Eos Stellarator. This engineer will be responsible for creating high-performance, reliable electronics to interface between control firmware, power conversion hardware, and diagnostics subsystems.

The role includes schematic capture, PCB layout, component selection, hardware bring-up, and cross-functional integration with power electronics, software, and system engineers. This is a hands-on, lab-focused role with a critical impact on the development of the control core of a fusion energy system.

• Design and develop custom embedded control boards including:
o ARM, DSP, and/or FPGA/SoC based controller boards
o ADC/DAC interfaces, digital I/O, sensor front-ends
o Gate driver boards and opto-isolated switching logic
• Generate schematics and PCB layouts with a focus on signal integrity, high-current and/or high-voltage handling, and isolation.
• Develop interface circuitry between embedded controllers and the power stage: current/voltage sensing, PWM outputs, fault inputs, and communication buses.
• Select and source components based on performance, reliability, and availability.
• Build and test prototypes, perform hardware bring-up, debugging, signal probing, and validation under operating conditions.
• Collaborate with embedded firmware developers to ensure hardware/software compatibility and deterministic real-time behavior.
• Work closely with power electronics engineers to ensure optimal mechanical, thermal, and electrical integration.
• Implement EMI/EMC mitigation techniques, isolation strategies, and power integrity best practices.

Required Qualifications:
• Bachelor’s or Master’s degree in Electrical Engineering, Electronics Engineering, or related field.
• 5+ years of experience in embedded hardware design for power systems, control systems, or instrumentation.
• Expertise in:
o Analog and mixed-signal circuit design
o High-speed digital interfaces (SPI, I2C, UART, RS-485, CAN, Aurora)
o Signal conditioning for sensors and actuators
• Proficiency in schematic capture and PCB layout tools: Altium Designer or OrCAD
• Hands-on experience with:
o Oscilloscopes, logic analyzers, and multimeters
o Board-level debugging, rework, and signal probing
• Strong understanding of PCB stackups, thermal design, creepage/clearance, and layout for high-current environments

Preferred Qualifications:
• Experience working on control electronics for power supplies, motor drives, or magnet systems
• Knowledge of gate driver design, isolation techniques, and fail-safe circuitry
• Familiarity with EMI/EMC compliance standards and mitigation techniques
• Exposure to RTOS- or FPGA-based control systems and real-time embedded integration

Tools & Platforms:
• Design Software: Altium Designer, OrCAD, LTSpice, PLECS (for co-design)
• Lab Tools: Oscilloscopes, spectrum analyzers, signal generators, logic analyzers
• Interfaces: UART, SPI, I2C, RS-485, RS-232, CAN, FlexRay, Aurora, PWM, ADC/DAC