Electro Mechanical Engineer

The Electro Mechanical Engineer designs and commissions bespoke reel-to-reel process machines that seamlessly integrate high-precision mechanical assemblies with advanced control systems. This role serves as a subject matter expert in roll-to-roll tension control, web handling, winding dynamics, and in-line process modules, with a focus on handling fragile, high-temperature superconducting tape to zero-defect standards. The engineer leads the design of electromechanical equipment, manages external vendors and integrators, and develops sophisticated in-line inspection and automation solutions to increase manufacturing throughput, yield, and reliability.

• Design hardware and controls for bespoke reel-to-reel process machines, ensuring tight integration between mechanical assemblies and complex control software.
• Act as the subject matter expert for machine design enabling roll-to-roll tension control, web handling and steering, winding dynamics, and in-line process modules.
• Scope and design electromechanical equipment capable of handling fragile high-temperature superconducting tape with zero-defect tolerance.
• Manage external vendors and system integrators for the fabrication of large-scale equipment, ensuring strict adherence to performance, quality, and safety standards.
• Design and implement advanced in-line inspection systems, such as computer vision and laser interferometry, to capture high-fidelity process data during continuous manufacturing.
• Develop long-term strategies to increase manufacturing throughput, including identifying bottlenecks in the reel-to-reel process and implementing automated solutions to improve yield and reliability.
• Use 3D CAD tools and simulation methods to validate machine designs and ensure robust performance under operational conditions.
• Provide technical guidance and collaboration support to manufacturing, design, and cross-functional engineering teams.
• Solve first-of-a-kind engineering challenges where no off-the-shelf solutions exist, driving innovation in equipment design and process control.

• BS, MS, or PhD in Mechatronics, Mechanical Engineering, Electrical Engineering, or a closely related field.
• 8+ years of experience in the electromechanical design and commissioning of complex reel-to-reel equipment, preferably in delicate material applications such as semiconductor, battery electrode, or specialized aerospace manufacturing.
• Proficiency in electro-mechanical design and machine design for high-precision, continuous manufacturing systems.
• Strong experience with tooling design for custom reel-to-reel machinery and associated process modules.
• Expertise with Beckhoff/TwinCAT 3 and EtherCAT, including structured text programming for advanced motion and process control.
• Experience with taper tension and specialized winding algorithms for roll-to-roll processes.
• Expert-level proficiency in 3D CAD software (NX preferred) for mechanical design and detailing.
• Experience using FEA or multibody dynamics simulation tools to validate and optimize machine designs.
• Proven ability to solve first-of-a-kind engineering problems and develop novel solutions where standard equipment or methods are not available.

• Background in designing equipment for delicate or high-value materials, such as high-temperature superconductors, semiconductor substrates, battery electrodes, or aerospace materials.
• Experience integrating computer vision systems and optical inspection technologies, including laser interferometry, into manufacturing equipment.
• Familiarity with continuous manufacturing environments and roll-to-roll process optimization.
• Strong vendor and integrator management skills, including specification, oversight, and acceptance testing of large-scale equipment.
• Ability to collaborate effectively with magnet engineers, plasma physicists, and multidisciplinary teams in a cutting-edge technology environment.
• Demonstrated ability to work independently and self-start on complex technical projects with minimal supervision.
• Strong analytical, problem-solving, and communication skills, with the ability to translate complex technical concepts into practical design and process decisions.

The role is based within a fast-growing fusion energy startup that has recently completed its prototyping phase and is transitioning toward production. The organization currently has around 100 employees and plans to scale to 150200 during its next funding phase and ultimately to approximately 1,000 employees over the next 23 years. The largest groups are magnet engineers specializing in high-temperature magnets and plasma physicists, creating a highly technical, collaborative environment focused on reinventing stellarator-based fusion using advanced, computer-controlled planar coil arrays. Senior and subject matter expert candidates may work fully remotely, with an expectation of strong self-direction and minimal training requirements. Mid-level candidates with 4+ years of experience are ideally able to work on a hybrid schedule onsite in New Jersey, combining in-person collaboration with remote flexibility. The work involves modern CAD, control, and simulation tools, as well as advanced inspection technologies, in a culture driven by innovation, sustainability, and the mission to deliver zero-emission fusion energy.

This is a Contract to Hire position based out of Kearny, NJ.

The pay range for this position is $64.90 - $79.33/hr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: Medical, dental & vision Critical Illness, Accident, and Hospital 401(k) Retirement Plan Pre-tax and Roth post-tax contributions available Life Insurance (Voluntary Life & AD&D for the employee and dependents) Short and long-term disability Health Spending Account (HSA) Transportation benefits Employee Assistance Program Time Off/Leave (PTO, Vacation or Sick Leave)

This is a Contract to Hire position based out of Kearny, NJ.

This position is anticipated to close on Nov 20, 2026.

This is a fully remote position.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on click.appcast.io for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.