Manufacturing Engineer

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 seasoned Manufacturing Engineer III to join our rapidly growing team. In this role, you will lead the development, validation, and scale-up of advanced manufacturing processes, complex tooling, and specialized equipment required to build and test high-temperature superconducting ("HTS") magnets. As a senior technical contributor, you will play a key role in establishing the frameworks for manufacturing development as we develop and prototype our stellarator systems.   

Key Responsibility Areas:

• Lead the development and standardization of manufacturing documentation for HTS magnets, including complex assembly procedures, work instructions, and rigorous quality inspection criteria.
• Own the end-to-end design, procurement, build, and commissioning of custom magnet manufacturing tooling, fixtures, and automated assembly equipment.
• Serve as the primary manufacturing liaison to the Magnet Engineering team, driving design for manufacturability, process FMEAs, and iterative design improvements from prototype to production.
• Architect and manage manufacturing BOMs, routings, and inventory workflows within PLM and MRP systems to ensure seamless execution.
• Author technical specifications, evaluate supplier capabilities, and partner with key vendors to procure high-precision hardware and capital equipment.
• Define technician roles, establish training programs, and mentor junior engineers and technical staff.
• Track, report, and take ownership of manufacturing milestones, schedule adherence, and budget constraints across primary magnet initiatives. 

Ideal Experience & Skillsets:

• Bachelor’s degree in Mechanical, Manufacturing, Aerospace, or Electrical Engineering (or related field) with 7+ years of hands-on manufacturing engineering experience.
• Extensive experience building complex electro-mechanical assemblies and introducing first-of-a-kind hardware processes into full-scale production.
• Proven background in advanced joining and metal fusion processes, including high-precision soldering, brazing, electron beam, or TIG welding.
• Demonstrated success scaling low-volume development projects into continuous production environments utilizing PLM, MRP, and ERP software platforms.
• Deep expertise in drafting and interpreting engineering drawings with comprehensive Geometric Dimensioning and Tolerancing (GD&T) per ASME Y14.5.