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Breakthrough Energy Ventures Portfolio Company Career Opportunities

Reverse-Engineering Specialist

Commonwealth Fusion Systems

Commonwealth Fusion Systems

Devens, MA, USA
Posted on Saturday, January 13, 2024
Commonwealth Fusion Systems (CFS) has the fastest, lowest cost path to commercial fusion energy.
CFS collaborates with MIT to leverage decades of research combined with groundbreaking new high-temperature superconducting (HTS) magnet technology. HTS magnets will enable compact fusion power plants that can be constructed faster and at lower cost. Our mission is to deploy these power plants to meet global decarbonization goals as fast as possible. To that end, 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. To implement this plan, we are looking to add dedicated people to the team who treat people well, improve our work by adding multifaceted perspectives and new ways of solving problems, have achieved outstanding results through a range of pursuits, and have skills and experience related to this role.
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 the Reverse Engineering Specialist, 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 Assembly Metrology Manager. 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 process 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.

This team member will:

  • Development, optimization, training, and use of the reverse-engineering workflow for all SPARC systems that require field-fit placement and alignment
  • Metrological data collection of structures and features on SPARC using laser-tracker, CMM arm, or other scanning technology
  • Management of the scanning data and datum systems, in accordance with the overall precision alignment plan
  • Careful use and application of the scanning 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. Maintain a well-ordered organization of all custom part models and work with the Procurement teams to ensure the appropriate data and models go to the correct machine shops for completion, as well as tracking, 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
  • Collaboration with other teams in adverse cases, creating and executing a workflow that allows efficient and expedient completion of mis-alignment issues
  • Assistance 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 Senior Metrology Engineer to ensure the plan as a whole is comprehensive and meets requirements
  • Assistance with field metrology activities conducted by the Senior Metrology Engineer 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
  • Optimization of measurement processes and setups for areas of improvement, and conduct risk assessment of measurement approaches and strategies

The ideal candidate will have most, if not all, of these requirements:

  • High school diploma completion
  • Minimum of 3+ years of experience working with engineering, manufacturing, or operations
  • 3+ years experience with common CAD software (Siemens NX, Solidworks, etc.)
  • Requires spatial awareness and the ability to describe positions and movements in 3D space
  • Requires basic mechanical aptitude including ability to read and interpret dimensions, tolerances, and assembly notes
  • 3+ years experience with laser tracking and scanning metrology tools, as well as a paired metrology software package (SpatialAnalyzer, Polyworks, DesignX, etc.)
  • 1+ years experience with CMM arm tools
  • 3+ years experience in handling, assembly, or installation of tightly toleranced structural components
  • 3+ years experience with Microsoft Excel
  • 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

Additional experience and/or qualifications:

  • 5+ years experience with laser tracking metrology tools
  • 5+ years experience with CMM arm tools
  • 5+ years experience with Siemens NX CAD software
  • 3+ years experience management of large data sets in Microsoft Excel or similar program
  • 3+ years experience with SpatialAnalyzer
  • 2+ years experience with CAM software
  • 2+ years experience conducting reverse-engineering activities, utilizing and applying metrology data to customize parts for as-built, tight-tolerance interfaces and high-precision location
  • 5+ years experience in handling, assembly, or installation of tightly toleranced structural components
  • Experience in table-top metrology processes and work, for small-scale components
  • Experience with precision alignment of large, delicate, and complex structures in dense spaces, involving multi-setup plans, incorporation of manufacturing tolerancing in tandem with field metrology, and component measurement transfers between multiple setups for multi-body alignment in software models previous to final field alignment
  • Experience with and expertise in GD&T
  • Ability to perform activities such as sitting, climbing, stooping, typing, and standing for extended periods of time
  • Willingness to occasionally travel for required nights/weekends/on-call
  • Dedication to safety to mitigate industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, and cryogenics
  • #LI-Onsite
CFS team members thrive in a fast-paced, dynamic environment and have demonstrated exceptional results through a range of different pursuits. We all tightly align with our company values of integrity, execution, impact and self-critique. As we grow, we are looking to add talented people who are mission driven and bring diverse perspectives and new ways of solving problems.
At CFS, we deeply value diversity and are an equal opportunity employer by choice. We consider all qualified applicants equally for employment. We do not discriminate on the basis 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, ordinance, or regulation.