Senior Mechanical Engineer, Accelerator Technology

ppSenior Mechanical Engineer, Accelerator Technology /p pMadison, WI /p pHelp design the high-performance hardware powering the future of fusion energy. This Senior Mechanical Engineer will lead the mechanical design and integration of ion sources, high-voltage systems, and RF hardware supporting Realta’s technology development roadmap. This role will be a critical contributor to Realta’s first‑of‑a‑kind fusion pilot plant, Hammir. The ideal candidate will work shoulder‑to‑shoulder with physicists, engineers, and technicians to commission and operate first‑of‑a‑kind fusion experiments in a fast‑moving environment. /p pRealta Fusion is a rapidly growing start‑up developing compact magnetic mirror fusion energy systems to address the biggest challenge of our time – tackling global climate change while ensuring a sufficient energy supply for at least ten billion people on (and off) earth. We are building a team with diverse talents dedicated to making fusion energy a real solution to humanity’s most pressing problem. /p h3Responsibilities /h3 ul liLead the mechanical design and integration of beamline components, ion source assemblies, extraction/acceleration grids, and associated accelerator equipment from concept through fabrication and commissioning. /li liDesign and specify high-voltage (HV) hardware – insulators, feedthroughs, HV power supplies, and ultra-high vacuum-compatible HV structures – ensuring reliable standoff and minimal breakdown risk. /li liOwn the mechanical design of RF components for accelerator systems, working closely with RF engineers to meet electromagnetic, thermal, and vacuum requirements. /li liPerform thermal, structural, electromagnetic, and vacuum analysis (e.g., using Ansys or COMSOL) to validate designs against operational loads and performance targets. /li liDesign for ultra-high vacuum (UHV) compatibility, including material selection, bakeout procedures, and joint/seal design for ion source and beamline subsystems. /li liDevelop detailed mechanical drawings, tolerances, and specifications suitable for precision machining, vendor quoting, and in-house fabrication. /li liLead or support assembly, integration, troubleshooting, and testing of ion sources and accelerator subsystems, including HV conditioning and RF commissioning. /li liCollaborate cross-functionally with physicists, RF/electrical engineers, and controls teams to translate physics requirements into manufacturable mechanical designs. /li liSupport design for manufacturability (DFM) and drive iterative improvements across prototype, first-build, and production phases. /li liContribute to technical documentation, safety protocols (HV and radiation safety), and design reviews. /li liMentor junior engineers and contribute to the technical growth of the mechanical engineering team. /li /ul h3Required Qualifications /h3 ul liEducation: BS in Mechanical Engineering or a related field, or equivalent experience /li liExperience: 5–10+ years of relevant industry or national‑lab experience, with demonstrated experience designing and building ion sources or particle accelerator components (linacs, cyclotrons, synchrotrons, or similar) /li liProficiency with CAD (SolidWorks, NX, or equivalent) and simulation tools (Ansys, COMSOL, or equivalent) for structural, thermal, and EM analysis /li liHands‑on experience with UHV design practices, vacuum hardware, and vacuum system troubleshooting /li liFamiliarity with precision fabrication methods and GDT for tight‑tolerance, high‑reliability hardware /li liAbility to work in a fast‑paced, multidisciplinary, and results‑driven start‑up environment /li liCollaboration: Exceptional interpersonal and communication skills (written, verbal, public presentation) to collaborate effectively with colleagues, external partners, and stakeholders /li /ul h3Preferred Qualifications /h3 ul liMaster’s Degree or higher in Mechanical Engineering or related field /li liProfessional Engineering (PE) license /li liExperience in designing for and working within radiation environments /li liExperience with cryogenic systems for ultra‑high vacuum applications /li liExperience with high‑voltage systems, megawatt‑scale heating and cooling systems, and specialty materials for fusion or particle accelerator applications /li /ul h3Compensation Benefits /h3 ul liCompetitive compensation package, including equity stock options /li liComprehensive benefits including health, dental, and vision insurance, plus a 401(k) /li liFlexible paid time off (PTO) to support work‑life balance /li liWork and live in Madison, Wisconsin — one of America’s most livable and vibrant cities /li /ul pWe value diversity as a critical factor in innovation and believe a diverse team is necessary to solve the toughest problems. We aim to create an inclusive environment that unleashes the full creativity of our team members from a wide variety of backgrounds and experiences. We provide equal employment opportunities to all individuals ba