Staff Dimensional Engineer – SPARC
Commonwealth Fusion · Devens, United States · 12d ago
SPARC is a first-of-a-kind machine, and it presents some of the hardest dimensional management problems in industry today: large high-field magnets, tight tolerances on complex geometries at meter scale, novel materials, and assembly stack-ups with no precedent to copy from. CFS is seeking a Staff Dimensional Engineer to be the technical authority for dimensional management across HTS Magnet production and the SPARC project.
This is a role for someone who wants to define a discipline, not inherit one. You will own how design intent becomes buildable, verifiable hardware: setting GD&T and datum strategy with Engineering, analyzing variation propagation through assembly sequences before hardware proves it the hard way, and defining what we measure and to what acceptance criteria. Your decisions will shape how fusion hardware is toleranced, measured, and accepted, on SPARC and on the ARC power plants that follow.
You will work alongside a metrology team equipped with laser trackers, portable CMM arms, and structured-light scanning, and with an established Quality Engineering organization that owns statistical process control and measurement system analysis, so your focus stays on the geometry.
What you'll do:
- Set GD&T and datum strategy in partnership with Engineering, translating design intent into tolerancing that is functionally sound and manufacturable with our equipment and fabrication methods
- Perform tolerance stack-up and 3D variation analysis on large complex assemblies, predicting variation propagation through build sequences and informing tooling, indexing, and assembly strategy
- Architect inspection requirements for large metallic components and assemblies, defining what to measure, how, and to what acceptance criteria
- Drive key characteristic identification and flowdown from top-level assembly requirements to component drawings and supplier requirements
- Support disposition of Non-Conformance Reports with dimensional analysis, quantifying the assembly-level impact of as-built deviations to inform use-as-is, rework, repair, or scrap decisions
- Review engineering change packages for dimensional impact as designs mature through SPARC assembly and integration
- Coach QC Inspectors, Quality Engineers, and Design Engineers on GD&T interpretation and dimensional management practice
What we’re looking for:
- BS in Mechanical, Industrial, Materials Science, Manufacturing, or Aerospace Engineering
- 10+ years of dimensional engineering experience on complex hardware (airframes, vehicle structures, turbomachinery, large equipment, or comparable)
- Mastery of GD&T (ASME Y14.5) as an author, not only an interpreter: datum strategy, tolerance allocation, and drawing review authority; GDTP certification strongly preferred
- Proven tolerance stack-up capability, both 1D (RSS, worst-case) and 3D variation analysis (3DCS, VisVA, or equivalent)
- Experience applying dimensional management to large assemblies: indexing strategies, key characteristics, and assembly sequence variation
- Demonstrated ability to translate design intent into inspection requirements and acceptance criteria
- Excellent communication and organization skills
Bonus points for:
- Experience standing up dimensional management practices in a new program or organization (NPI, clean-sheet aircraft or vehicle programs)
- Working knowledge of SPC, process capability analysis, MSA/Gage R&R, and PFMEA
- Familiarity with metrology instruments applied to complex geometries (laser tracker, portable arms, CMM, structured light)
- Knowledge of NDE methods (PT, UT, ET, RT)
- Knowledge of cryogenics
- Minitab or JMP; MS Excel (including VBA); MS Visio
Must-have Requirements:
- Ability to occasionally lift up to 50 lbs
- Willingness to travel or work required nights/weekends/on-call occasionally
- Perform activities such as stooping, climbing, typing, standing, or sitting for extended periods of time
- Work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics