Senior Mechanical Engineer (Welding and Remote Operations)

Position Overview

Join Type One Energy in our mission to commercialize fusion energy. As a Senior Mechanical Engineer – Welding and Remote Operations based in Knoxville, TN, you will play a pivotal role in designing, developing, and implementing complex mechanical systems and tooling solutions integral to our fusion energy programs. Working under the guidance of the VP Stellarator Maintenance and Inspection, you will support maintenance, repair, and overhaul of high‐precision manufactured fusion components, ensuring our breakthrough fusion energy initiatives stay on track.

Employment Type: Permanent, Full Time | Salary: Highly Competitive Plus Benefits

Key Responsibilities

• Lead the design and integration of mechanical tooling, fixtures, and automated systems used for welding, assembly, and component handling.
• Develop and refine weld processes, including parameter optimization, sequence development, and validation for advanced materials and geometries.
• Design and qualify remote or automated systems for operation in constrained, hazardous, or high-radiological environments.
• Serve as a subject matter expert for welding and mechanical tooling design, advising cross-functional teams in manufacturing, materials, and systems engineering.
• Review, guide, and validate designs created by peers and external suppliers to ensure technical excellence and manufacturability.
• Support FMEA, DFMA, and risk assessments for critical hardware and assemblies.
• Collaborate with suppliers and internal teams to support fabrication, assembly, and qualification of mechanical systems.
• Develop and execute test plans to validate tool performance, weld quality, and automation repeatability.
• Author detailed engineering drawings, procedures, and specifications in compliance with quality and safety standards.
• Contribute to process development documentation, design reviews, and configuration control processes.

Required Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Manufacturing Engineering, or a related discipline.
• 15+ years of experience in mechanical design, manufacturing process development, or tooling engineering.
• Proven experience in welding tooling or weld process development (e.g., TIG, EB, laser, or friction stir welding).
• Experience in designing tooling and systems for remote or automated operations (e.g., robotic arms, manipulators, or teleoperated systems).
• Demonstrated experience integrating sensors, controls, or actuation systems into complex mechanical designs.
• Proficiency with 3D CAD tools (SolidWorks, Siemens NX, or similar) and PLM/PDM systems.
• Strong understanding of mechanical design principles, precision tolerancing, and manufacturing processes.

Preferred Qualifications

• Experience designing equipment or processes for high-radiological or nuclear environments, or for other extreme service conditions.
• Familiarity with automation, robotics, or mechatronic systems used in precision manufacturing.
• Knowledge of welding qualification standards (e.g., ASME, AWS, ISO) and prior work in a regulated engineering environment.
• Demonstrated success leading complex engineering projects from concept to production.

Benefits & Perks

• Highly Competitive Salary with yearly bonus
• Stock and share options
• Relocation allowance
• Insurance plans
• 401k retirement options
• And many more great voluntary benefits