SPARC is a first-of-a-kind machine, and it presents some of the hardest dimensional management problems in industry today: large high-field magnets, tight tolerances on complex geometries at meter scale, novel materials, and assembly stack-ups with no precedent to copy from. CFS is seeking a Staff Dimensional Engineer to be the technical authority for dimensional management across HTS Magnet production and the SPARC project.
This is a role for someone who wants to define a discipline, not inherit one. You will own how design intent becomes buildable, verifiable hardware: setting GD&T and datum strategy with Engineering, analyzing variation propagation through assembly sequences before hardware proves it the hard way, and defining what we measure and to what acceptance criteria. Your decisions will shape how fusion hardware is toleranced, measured, and accepted, on SPARC and on the ARC power plants that follow.
You will work alongside a metrology team equipped with laser trackers, portable CMM arms, and structured-light scanning, and with an established Quality Engineering organization that owns statistical process control and measurement system analysis, so your focus stays on the geometry.
What you'll do:
- Set GD&T and datum strategy in partnership with Engineering, translating design intent into tolerancing that is functionally sound and manufacturable with our equipment and fabrication methods
- Perform tolerance stack-up and 3D variation analysis on large complex assemblies, predicting variation propagation through build sequences and informing tooling, indexing, and assembly strategy
- Architect inspection requirements for large metallic components and assemblies, defining what to measure, how, and to what acceptance criteria
- Drive key characteristic identification and flowdown from top-level assembly requirements to component drawings and supplier requirements
- Support disposition of Non-Conformance Reports with dimensional analysis, quantifying the assembly-level impact of as-built deviations to inform use-as-is, rework, repair, or scrap decisions
- Review engineering change packages for dimensional impact as designs mature through SPARC assembly and integration
- Coach QC Inspectors, Quality Engineers, and Design Engineers on GD&T interpretation and dimensional management practice
What we’re looking for:
- BS in Mechanical, Industrial, Materials Science, Manufacturing, or Aerospace Engineering
- 10+ years of dimensional engineering experience on complex hardware (airframes, vehicle structures, turbomachinery, large equipment, or comparable)
- Mastery of GD&T (ASME Y14.5) as an author, not only an interpreter: datum strategy, tolerance allocation, and drawing review authority; GDTP certification strongly preferred
- Proven tolerance stack-up capability, both 1D (RSS, worst-case) and 3D variation analysis (3DCS, VisVA, or equivalent)
- Experience applying dimensional management to large assemblies: indexing strategies, key characteristics, and assembly sequence variation
- Demonstrated ability to translate design intent into inspection requirements and acceptance criteria
- Excellent communication and organization skills
Bonus points for:
- Experience standing up dimensional management practices in a new program or organization (NPI, clean-sheet aircraft or vehicle programs)
- Working knowledge of SPC, process capability analysis, MSA/Gage R&R, and PFMEA
- Familiarity with metrology instruments applied to complex geometries (laser tracker, portable arms, CMM, structured light)
- Knowledge of NDE methods (PT, UT, ET, RT)
- Knowledge of cryogenics
- Minitab or JMP; MS Excel (including VBA); MS Visio
Must-have Requirements:
- Ability to occasionally lift up to 50 lbs
- Willingness to travel or work required nights/weekends/on-call occasionally
- Perform activities such as stooping, climbing, typing, standing, or sitting for extended periods of time
- 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
Skills Required
- Bachelor’s degree in Mechanical, Industrial, Materials Science, Manufacturing, or Aerospace Engineering
- 10 or more years of dimensional engineering experience on complex hardware
- Mastery of GD&T and ASME Y14.5, including datum strategy, tolerance allocation, and drawing review authority
- Tolerance stack-up experience using 1D methods such as RSS and worst-case analysis
- 3D variation analysis experience using 3DCS, VisVSA, or equivalent
- Experience applying dimensional management to large assemblies, including indexing strategies, key characteristics, and assembly-sequence variation
- Ability to translate design intent into inspection requirements and acceptance criteria
- Excellent communication and organization skills
- GDTP certification
- Experience establishing dimensional management practices in a new program or organization
- Working knowledge of SPC, process capability analysis, MSA, Gage R&R, and PFMEA
- Familiarity with laser trackers, portable CMM arms, CMMs, or structured-light scanning
- Knowledge of NDE methods including PT, UT, ET, and RT
- Knowledge of cryogenics
- Experience with Minitab, JMP, Microsoft Excel including VBA, or Microsoft Visio
- Ability to occasionally lift up to 50 pounds
- Willingness to travel or work occasional nights, weekends, or on-call shifts
- Ability to perform stooping, climbing, typing, standing, or sitting for extended periods
- Ability to work in a facility with industrial hazards, strong magnets, high voltage, pressure systems, and cryogenics
What We Do
Commonwealth Fusion Systems (CFS) has the fastest, lowest cost path to commercial fusion energy. CFS is collaborating with MIT to leverage decades of research combined with new groundbreaking high-temperature superconducting (HTS) magnet technology. HTS magnets will enable compact fusion power plants that can be constructed faster and at lower cost. CFS is now building SPARC, the world's first commercially relevant, net energy fusion demonstration device. SPARC will pave the way for the first fusion power plant, ARC, that will produce power on the grid. The ultimate mission is to deploy fusion power plants to meet global decarbonization goals as fast as possible. CFS has assembled a team of leaders in tough tech, fusion science, and manufacturing with a track record of rapid execution. Supported by the world’s leading investors, CFS is uniquely positioned to deliver limitless, clean, fusion power to combat climate change. If you are interested in joining our team, check out cfs.energy/careers for more information.
