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Thea Energy

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Senior Manufacturing Engineer

KearnyOn-siteFull-time

AI Summary

Defines the long-term manufacturing roadmap and capital equipment strategy for HTS magnet production, leads process engineering and supplier relationships, and mentors manufacturing engineers.

About this role

About Thea Energy:
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.
Position Overview:

Thea Energy is seeking a Senior Manufacturing Engineer to serve as a technical leader and strategic driver within our operations group. In this role, you will be responsible for defining the long-term manufacturing roadmap, capital equipment strategy, and operational scale-up for our high-temperature superconducting ("HTS") magnet production. Beyond driving complex manufacturing engineering challenges, you will mentor engineering and production staff, develop organizational process workflows, and interface directly with executive leadership. This role is vital to transforming cutting-edge fusion physics into scalable, commercial-grade hardware.

Key Responsibility Areas:

  • Establish the manufacturing architecture, factory layout, and process methodologies for HTS magnet production and facility commissioning.
  • Partner with design and physics leaders to guarantee design for manufacturability and cost-optimization from initial concepts through prototyping and beyond.
  • Direct the design, acquisition, installation, and qualification of high-value capital equipment, custom tooling, and automated manufacturing systems.
  • Architect foundational Process Engineering frameworks, root-cause corrective action protocols, and continuous improvement initiatives.
  • Lead key technical relationships with major suppliers and contract manufacturers to secure critical hardware and resolve complex supply chain bottlenecks.
  • Provide technical guidance and mentorship to Manufacturing Engineers and technical personnel; assist leadership in team scaling and organizational design.
  • Own program delivery schedules, risk mitigations, and capital expenditure tracking, regularly communicating updates to key internal and external stakeholders.

    • Ideal Experience & Skillsets:

  • Bachelor’s or Master’s degree in Engineering with 10+ years of progressive manufacturing engineering experience in high-tech, regulated, or precision hardware environments.
  • Proven track record of taking complex, first-of-a-kind electro-mechanical systems from concept through factory floor commissioning and volume ramp.
  • Expert knowledge of precision mechanical assembly, thermal processing, coil winding, and metal fusion methodologies (soldering, brazing, specialized welding).
  • In-depth experience managing large-scale custom capital tooling projects and integrating automated assembly workflows.
  • Deep expertise in GD&T, statistical process control (SPC), PFMEA, and modern enterprise software systems (PLM, MRP, ERP).
  • Background in aerospace, magnetic confinement fusion, nuclear systems, medical devices, or high-complexity technology hardware.
  • Outstanding leadership, project management, and inter-personal communication skills with a history of driving alignment across cross-functional groups.
  • Ability to occasionally lift objects up to 50 lbs.

    • Skills

    Automated Assembly WorkflowsBrazingCapital Tooling Project ManagementCoil WindingContinuous ImprovementDesign For ManufacturabilityERPFactory Layout PlanningGD&TMRPPFMEAPLMPrecision Mechanical AssemblyRoot-cause Corrective ActionSolderingSpecialized WeldingStatistical Process ControlThermal Processing

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