Manufacturing Engineering, Assembly

Manufacturing Engineer IIIKearny, NJTechnology – Manufacturing Engineering /On-site

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.

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.

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.

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.Experience in magnetic confinement fusion, aerospace, medical devices, defense, or high‑reliability advanced manufacturing sectors.

Diversity and Inclusion:

Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran’s status, or other characteristic protected by applicable laws and regulations.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information.