Senior Mechanical Engineer,Accelerator Technology Job Madison area,Wisconsin USA,Engineering

Help 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.

Realta 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.

Responsibilities

Lead the mechanical design and integration of beamline components, ion source assemblies, extraction/acceleration grids, and associated accelerator equipment from concept through fabrication and commissioning.

Design 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.

Own the mechanical design of RF components for accelerator systems, working closely with RF engineers to meet electromagnetic, thermal, and vacuum requirements.

Perform thermal, structural, electromagnetic, and vacuum analysis (e.g., using Ansys or COMSOL) to validate designs against operational loads and performance targets.

Design for ultra-high vacuum (UHV) compatibility, including material selection, bakeout procedures, and joint/seal design for ion source and beamline subsystems.

Develop detailed mechanical drawings, tolerances, and specifications suitable for precision machining, vendor quoting, and in-house fabrication.

Lead or support assembly, integration, troubleshooting, and testing of ion sources and accelerator subsystems, including HV conditioning and RF commissioning.

Collaborate cross-functionally with physicists, RF/electrical engineers, and controls teams to translate physics requirements into manufacturable mechanical designs.

Support design for manufacturability (DFM) and drive iterative improvements across prototype, first-build, and production phases.

Contribute to technical documentation, safety protocols (HV and radiation safety), and design reviews.

Mentor junior engineers and contribute to the technical growth of the mechanical engineering team.

Required Qualifications

Education:

BS in Mechanical Engineering or a related field, or equivalent experience

Experience:

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)

Proficiency with CAD (Solid Works, NX, or equivalent) and simulation tools (Ansys, COMSOL, or equivalent) for structural, thermal, and EM analysis

Hands‑on experience with UHV design practices, vacuum hardware, and vacuum system troubleshooting

Familiarity with precision fabrication methods and GD&T for tight‑tolerance, high‑reliability hardware

Ability to work in a fast‑paced, multidisciplinary, and results‑driven start‑up environment

Collaboration:

Exceptional interpersonal and communication skills (written, verbal, public presentation) to collaborate effectively with colleagues, external partners, and stakeholders

Preferred Qualifications

Master’s Degree or higher in Mechanical Engineering or related field

Professional Engineering (PE) license

Experience in designing…

Senior Mechanical Engineer, Accelerator Technology