Staff Quality Engineer - Advanced Metrology Integration

About Commonwealth Fusion Systems:  Commonwealth Fusion Systems is on a mission to deliver the urgent transition to fusion energy. Combining decades of research, top talent, and new technologies, we’re designing and building commercially viable fusion power plants. And we're working with policymakers and suppliers to build the energy industry of the future.  We’re in the best position to make it happen. Since 2018, we’ve raised nearly $3 billion in capital, making us the largest and leading private fusion company in the world. Now we’re looking for more thinkers, doers, builders, and makers to join us. People who’ll bring new perspectives, solve tough problems, and thrive as part of a team.  If that’s you and this role fits, we want to hear from you. Join the power movement as 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:

• 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:

• BS in Mechanical, Industrial, Material Science or Manufacturing Engineering
• 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 9001-2015, 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