Quality Engineer - Advanced Metrology Integration

Staff Quality Engineer - Advanced Metrology Integration

Commonwealth Fusion Systems (CFS) is seeking a Staff Quality Engineer to serve as the subject matter expert (SME) for dimensional management and quality strategy for our HTS Magnet production and the SPARC Project. In this high-impact role, you will be the technical authority on Geometric Dimensioning and Tolerancing (GD&T), ensuring that novel, first-of-a-kind designs are translated into manufacturable and verifiable hardware.

In this capacity, you will act as the technical authority for translating novel, first-of-a-kind design requirements into manufacturable reality. You will partner closely with Engineering to understand design intent and work to better define GD&T requirements that are more manufacturable, while architecting the inspection systems, tooling, and process controls necessary for HTS Magnet production. Serving as the subject matter expert in GD&T, you will resolve complex fabrication challenges with risk-informed quality strategies that directly enable the SPARC project mission.

What you'll do:

• Manufacturing-Driven GD&T Interpretation:
  Partner closely with Engineering to understand design intent and define more manufacturable GD&T requirements; work directly with Manufacturing Engineers to determine how to achieve critical tolerances using existing equipment and novel fabrication methods
• Proactive Problem Solving:
  Lead the development of risk-informed QA controls that bridge the gap between design intent and shop-floor reality to positively impact the CFS mission
• Inspection Architecture:
  Architect measurement systems and quality inspection methods specifically designed for the assembly of large metallic components, moving beyond theoretical models to executable floor-level plans
• Disposition Leadership:
  Provide risk-informed leadership to design engineers in dispositioning Non-Conformance Reports (NCRs) across the full range of outcomes (use-as-is, rework, repair, scrap), grounded in structural integrity and functional requirements
• Process Stabilization:
  Regularly analyze manufacturing data using control charts and process capability studies to identify emerging process drift, escalating insights to Operations to drive immediate process adjustments
• Sub-system Integration:
  Facilitate the creation and execution of PFMEAs and Quality Plans for the installation of sub-systems, ensuring that assembly tolerances are managed as the SPARC project scales
• Measurement System Analysis (MSA):
  Lead advanced MSA and Gage R&R studies to ensure that the methods used to measure novel designs are statistically sound and repeatable in a production environment
• Mentorship & Oversight:
  Provide technical coaching to QC Inspectors and Quality Engineers, specifically regarding GD&T interpretation on the shop floor

What we're looking for:

• Minimum 10+ years of Quality Engineering experience in a manufacturing, assembly or equipment manufacturing environment, specifically focused on transitioning new products to production
• Demonstrated program-level ownership of dimensional management or quality strategy, not solely execution of inspection plans defined by others
• Proven experience architecting inspection systems and measurement strategies for complex hardware, including defining what to measure, how, and to what acceptance criteria
• GD&T Expertise:
  Mastery of GD&T (ASME Y14.5) with a proven ability to translate theoretical tolerances into practical manufacturing work instructions
• Metrology:
  Deep knowledge of CMM, Romer Arm, and Laser tracker applied to complex geometries
• ISO , Six Sigma, Statistical Process Control (SPC), Process Capability Analysis, PFMEA, Measurement System Analysis (MSA), APQP
• GD&T and Metrology (Required)
• Knowledge of NDE (non-destructive evaluation) methods including dye penetrant, ultrasonic, eddy current, and x-ray (Preferred)
• Knowledge of cryogenics (Preferred)
• Minitab or JMP, MS Excel (including VBA), MS Visio
• Excellent communication and organization skills

Bonus points for:

• Manufacturing
  
  Experience:
  
  NPI in a low volume environment
• Mentorship & Oversight:
  Proven ability to provide technical coaching and indirect leadership to QC inspectors and quality engineering teams
• Statistical Tools:
  Proficiency in Minitab or JMP for conducting Process Capability Analysis and Six Sigma methodologies

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

$130,000 - $200,000 a year Salary range for this full-time position + equity + benefits. The actual salary will depend on level, location, qualifications, and experience. The range displayed on each job posting reflects new hire salaries for the position across all US…