The Role
Leads the end-to-end design, fabrication, testing, commissioning, and factory deployment of large custom tooling, lifting rigs, fixtures, and handling equipment for fusion hardware. Responsibilities include structural analysis, supplier management, DFM/DFA, rigging safety, assembly planning, precision alignment, metrology, work instructions, and hands-on integration support for complex multi-ton systems.
Summary Generated by Built In
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:
Key Responsibility Areas:
- Lead the full design, analysis, procurement, fabrication, and commissioning of large, heavy custom tooling, fixtures, and jigs for manufacturing and test.
- Develop custom lifting rigs, spreader bars, turn-over fixtures, and heavy handling equipment while establishing safe rigging protocols for multi-ton hardware.
- Define structural, mechanical, interface, and safety requirements for custom tooling, ensuring compliance with applicable lifting and rigging safety standards.
- Manage vendor and fabrication shop relationships for the build, machining, proof-load testing, and delivery of heavy tooling assemblies.
- Drive Design-for-Manufacturability (DFM) and Design-for-Assembly (DFA) input into design engineering to optimize hardware interfaces for custom tooling and handling.
- Support development of physical assembly, installation, and integration sequences for complex nuclear and industrial hardware.
- Define precise tooling requirements for positioning, joining, inspection, testing, and precision metrology alignment strategies.
- Develop detailed work instructions, lift plans, and operational procedures for heavy tooling setup, component maneuvering, and factory integration.
- Identify, manage, and resolve tooling-related safety, structural, and integration risks before hardware reaches final assembly.
- Support prototype builds, first-of-a-kind hardware integration, factory/field assembly, and hands-on trouble shooting during hardware operations.
Ideal Experience & Skillsets:
- 8+ years of progressive experience in custom tooling design, mechanical engineering, heavy equipment design, or hardware integration.
- Proven track record of designing, building, and deploying large, heavy custom tooling, multi-ton fixtures, lift frames, or specialized assembly equipment.
- Direct familiarity and hands-on exposure to rigging principles, heavy lifting practices, spreader bar design, crane operations, and load testing standards.
- Expert knowledge of structural design, welded steel structures, stress analysis, GD&T, tolerance stack-up, and mechanical interfaces.
- Expertise in 3D CAD modeling (NX preferred) and finite element analysis in COMSOL or Ansys for custom machined/welded structures.
- Experience developing assembly and integration processes, DFM/DFA, and hands-on support for manufacturing and installation.
- Experience with precision alignment, metrology tools (e.g., laser trackers), and large electro-mechanical hardware assembly.
- Background in nuclear, aerospace, fusion, heavy equipment, shipbuilding, semiconductor, or other highly engineered hardware industries.
- Strong interpersonal communication and cross-functional leadership skills, with the ability to work hands-on with design, manufacturing, and rigging teams.
Company Benefits:
- Salary Range $130,000- $155,000
- Comprehensive health benefits (e.g. medical/dental/vision)
- Employee equity stock options
- 20 days PTO
It’s not necessary to meet all of the skillsets outlined above. Please feel free to send us a note and tell us why you would still be a great fit for this role or Thea Energy.
Diversity and Inclusion:
Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. By creating a diverse environment, we will bring new ideas and approaches to solving some of the world’s hardest (and most important) problems. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran’s status, or other characteristic protected by applicable laws and regulations.
Skills Required
- 8+ years of progressive experience in custom tooling design, mechanical engineering, heavy equipment design, or hardware integration
- Experience designing, building, and deploying large heavy custom tooling, multi-ton fixtures, lift frames, or specialized assembly equipment
- Hands-on familiarity with rigging principles, heavy lifting practices, spreader bar design, crane operations, and load testing standards
- Expertise in structural design, welded steel structures, stress analysis, GD&T, tolerance stack-up, and mechanical interfaces
- Expertise in 3D CAD modeling, preferably NX, and finite element analysis using COMSOL or Ansys
- Experience developing assembly and integration processes, DFM/DFA, and supporting manufacturing and installation hands-on
- Experience with precision alignment, metrology tools such as laser trackers, and large electromechanical hardware assembly
- Background in nuclear, aerospace, fusion, heavy equipment, shipbuilding, semiconductor, or other highly engineered hardware industries
- Strong interpersonal communication and cross-functional leadership skills
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The Company
What We Do
Thea Energy is a fusion energy company dedicated to creating a limitless source of zero-emission energy for a sustainable future. By reinventing the stellarator using arrays of mass-manufacturable magnets and dynamic software controls, they aim to commercialize scalable and economical fusion power systems, transitioning from scientific research to practical, commercial operations.
