Metrology Engineer

Job Description

Commonwealth Fusion Systems is on a mission to deliver the urgent transition to fusion energy.

Combining decades of research, top talent and new technologies, we’re designing and building commercially viable fusion power plants. And working with policymakers and suppliers to build the energy industry of the future.

We’re in the best position to make it happen. Since 2018, we’ve raised over $2 billion in capital – more than any other fusion energy company in the U.S.

Now we’re looking for more thinkers, doers, builders, and makers to join us. People who’ll bring new perspectives, solve tough problems, and thrive as part of a team.

If that’s you and this role fits, we want to hear from you.

Join the power movement as a Metrology Engineer

CFS is an innovative clean energy company designing SPARC, a tokamak-style fusion power demonstrator able to achieve net energy plasmas. This demonstrator will lead to ARC, a power-plant scale fusion power generator system. SPARC includes high-temperature superconducting and copper magnets, thermal shields, cryogenic cooling systems, vacuum vessels, and plasma facing components, all of which are densely packed into a power system and are subject to large operational loads (thermal, electromagnetic, etc.). Critical to the success and performance of the device is the precise alignment and assembly of key systems and structures within the dense device assembly. Specifically, a number of these systems will require reverse engineering of their shapes using input from metrology data to match the shape of interfacing systems, so as to align and connect them in the correct location. As a Metrology Engineer focusing on reverse engineering, your responsibility will be ownership and management of the process from start to finish: development of the reverse-engineering workflow, collection of metrological data in the field, management of that data, easy and straightforward transfer to the part models for machining, and then organization and verification of the parts after completion and assembly. This work will be conducted for a wide variety of unique SPARC systems and structures, working within the overall precision alignment plan of SPARC managed by the Manager of SPARC Metrology. This process will be key to bringing cutting-edge metrology, CAD, and machining techniques to enable CFS to build this compact fusion device in a simpler, more practical, and faster than has ever been achieved before, paving the way for this process to be utilized and optimized in the next-generations ARC devices to enable their fast construction.

We are a fast-paced, agile, growing company that values diversity of thought and creativity, looking to apply our knowledge to pioneer a new method of energy generation for the betterment of the world. We look for people who have bold new ideas and perspectives, enthusiasm, imagination, a pioneering spirit, and a talent for execution to join us in our endeavor to create new fusion power technology that could change the world.

What you'll do

• Develop, optimize, execute, and train the reverse engineering workflow for all SPARC systems that require field-fit placement and alignment
• Collect metrology data of structures and features on SPARC using laser-tracker, CMM arm, or other contact or non-contact scanning technology
• Manage the scanning data and datum systems, in accordance with the overall precision alignment plan
• Careful use and application of scan data to all components to be reverse engineered; responsible for ideal data projection onto the pre-machined models, and the final model modification of all parts into their custom, field-fit forms to meet interface and alignment requirements
• Manage the status and movement of reverse-engineered components. Maintaining a well-ordered organization of all custom part models and working with the procurement teams to ensure that the appropriate data and models go to the correct machine shops for completion, as well as tracking, and indexing, and carefully organizing storage of thousands of individual completed custom parts
• Review of all results from reverse engineering alignment activities, confirming good placement of systems as required after assembly is complete
• Collaborate with other teams to create and execute a workflow that allows efficient and expedient completion of deviated alignment issues
• Assist in detailed process planning, development, and analysis of critical reverse engineering activities that overlap with the overall precision alignment plan of other major SPARC components, and working with the Metrology Engineering team to ensure the plan is comprehensive and meets requirements
• Assist with field metrology activities conducted by the Metrology Engineering team for other alignments as needed (laser-tracking, CMM arm, 3D scanning, etc.)
• Work in collaboration with Physics teams to develop the error-field bounding plan and approach, and that the characteristics and capabilities of tooling, system hardware, and overall strategy can accomplish alignments within maximum limits as outlined in this plan
• Perform uncertainty evaluation and analysis for measurement standards and associated measurement
• Optimize measurement setups and processes, and conduct risk assessment of measurement approaches and strategies

What we’re looking for

• High School Diploma or equivalent
• 3+ years experience working with engineering, manufacturing, or operations
• 3+ years experience using portable metrology and non-contact scanning tools in combination with portable metrology software packages
• 2+ years experience with common industry CAD software
• 3+ years experience using 3D point cloud data to develop detailed and accurate meshes of complex contoured surfaces
• Basic knowledge of GD&T
• Spatial awareness and the ability to clearly describe positions and movements in 3D space
• Basic mechanical aptitude including the ability to read and interpret design dimensions, tolerances, and assembly requirements
• Handling, assembly, and installation of tightly-toleranced structural components
• Ability to clearly express and critique ideas
• Excellent organization and careful management of large data sets
• Attention to detail
• Emphasis on elegance and simplicity over complexity
• Driven towards execution and rapid completion
• Understanding manufacturing methods and their impact on designs
• Drive towards commercially viable solutions
• Values that align with our company’s values of integrity, execution, impact, and self-critique
• Ability to analyze and evaluate test requirements and specifications to determine proper equipment specifications and calibration levels
• Excellent communication skills, ability to multitask
• Project Management- Excellent data handling, documentation, critical milestone creation, and organization skill

Bonus points for

• 5+ years experience using laser trackers, CMM arms, and non-contact scanning instruments (laser scanner, structured light scanner, photogrammetry)
• 5+ years experience using SpatialAnalyzer and Polyworks software packages
• 3+ years experience using Siemens NX CAD software
• 3+ years experience management of large data sets across multiple software platforms
• 3+ years experience conducting reverse-engineering activities, utilizing and applying point cloud data to customize parts for as-built, tight-tolerance interfaces and high-precision positioning
• Experience with precision alignment of large, delicate, and complex structures in dense spaces involving multi-setup plans
• Experience incorporating manufacturing tolerances with field metrology data to ensure proper alignment
• Experience performing virtual alignments using metrology data from multiple components to ensure adequate clearances and final assemblability
• Experience in table-top metrology processes and work, for small-scale components
• Advanced level GD&T knowledge

Must-have Requirements

• Ability to occasionally lift up to 50 lbs
• Perform activities such as sitting, climbing, stooping, typing, and standing for extended periods of time
• Working from heights is required. Must be able to safely utilize fall protection for work at heights of up to 35 feet via MEWPs (i.e. boom lift, scissor lift), temporary platforms (i.e. scaffolding, custom platforms), and ladders when necessary.
• Ability to work in confined, tight, or awkward spaces
• Work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics
• Willingness to travel or work required nights/weekends/on-call occasionally based on evolving build schedule

$80,000 - $180,000 a year

Salary range for this full-time position + equity + benefits. The actual salary will depend on level, location, qualifications, and experience. The range displayed on each job posting reflects new hire salaries for the position across all US locations. Benefits include:

• Competitive compensation with equity
• 12.5 Company-wide Holidays
• Flexible vacation days
• 10 sick days
• Generous parental leave policy
• Health, dental, and vision insurance
• 401(k) with employer matching
• Professional growth opportunities
• Team-building activities

At CFS, we excel in fast-paced environments, driven by our values of integrity, execution, impact, and self-critique. As we grow, we’re eager to bring on mission-driven folks who offer diverse perspectives and fresh ways to tackle challenges.

We value diversity deeply and are proud to be an equal opportunity employer by choice. We consider all qualified applicants equally, regardless of race, color, national origin, ancestry, citizenship status, protected veteran status, religion, physical or mental disability, marital status, sex, sexual orientation, gender identity or expression, age, or any other basis protected by law.