Electronics Hardware Design Engineer

Kearny, NJ
Technology – Electrical and Control Systems Engineering /
Full-time /
On-site
About Thea Energy:
Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.
Position Overview:
Thea Energy is seeking a highly skilled Electronics Hardware Design Engineer to lead the design and development of electronics, power electronics, and embedded control hardware for the Power Supply Systems, and Data Acquisition Units for the Control System of the Eos Stellarator. This engineer will be responsible for creating high-performance, reliable electronics to interface between control firmware, power conversion hardware, and diagnostics subsystems.
The role includes schematic capture, PCB layout, component selection, hardware bring-up, and cross-functional integration with power electronics, software, and system engineers. This is a hands-on, lab-focused role with a critical impact on the development of the control core of a fusion energy system.

Key Responsibility Areas:

• Design and develop custom embedded control boards including:
o ARM, DSP, and/or FPGA/SoC based controller boards
o ADC/DAC interfaces, digital I/O, sensor front-ends
o Gate driver boards and opto-isolated switching logic
• Generate schematics and PCB layouts with a focus on signal integrity, high-current and/or high-voltage handling, and isolation.
• Develop interface circuitry between embedded controllers and the power stage: current/voltage sensing, PWM outputs, fault inputs, and communication buses.
• Select and source components based on performance, reliability, and availability.
• Build and test prototypes, perform hardware bring-up, debugging, signal probing, and validation under operating conditions.
• Collaborate with embedded firmware developers to ensure hardware/software compatibility and deterministic real-time behavior.
• Work closely with power electronics engineers to ensure optimal mechanical, thermal, and electrical integration.
• Implement EMI/EMC mitigation techniques, isolation strategies, and power integrity best practices.

Ideal Experience & Skillsets:

Required Qualifications:
• Bachelor’s or Master’s degree in Electrical Engineering, Electronics Engineering, or related field.
• 5+ years of experience in embedded hardware design for power systems, control systems, or instrumentation.
• Expertise in:
o Analog and mixed-signal circuit design
o High-speed digital interfaces (SPI, I2C, UART, RS-485, CAN, Aurora)
o Signal conditioning for sensors and actuators
• Proficiency in schematic capture and PCB layout tools: Altium Designer or OrCAD
• Hands-on experience with:
o Oscilloscopes, logic analyzers, and multimeters
o Board-level debugging, rework, and signal probing
• Strong understanding of PCB stackups, thermal design, creepage/clearance, and layout for high-current environments

Preferred Qualifications:
• Experience working on control electronics for power supplies, motor drives, or magnet systems
• Knowledge of gate driver design, isolation techniques, and fail-safe circuitry
• Familiarity with EMI/EMC compliance standards and mitigation techniques
• Exposure to RTOS- or FPGA-based control systems and real-time embedded integration

Tools & Platforms:
• Design Software: Altium Designer, OrCAD, LTSpice, PLECS (for co-design)
• Lab Tools: Oscilloscopes, spectrum analyzers, signal generators, logic analyzers
• Interfaces: UART, SPI, I2C, RS-485, RS-232, CAN, FlexRay, Aurora, PWM, ADC/DAC

Company Benefits:

  • Salary range $110,000-$150,000
  • Comprehensive health benefits (e.g. medical/dental/vision)
  • Employee equity stock options
  • 20 days PTO

Requirements:

  • Ability to occasionally lift up to 50 lbs.
  • Ability to perform activities such as typing, standing, or sitting for extended periods of time.
  • Willingness to occasionally travel or work required nights/weekends/on-call.
  • Ability to work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, high voltage, high current, pressure systems, and cryogenics.
It’s not necessary to meet all of the skillsets outlined above. Please feel free to send us a note and tell us why you would still be a great fit for this role or Thea Energy.
Diversity and Inclusion:
Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. By creating a diverse environment, we will bring new ideas and approaches to solving some of the world’s hardest (and most important) problems. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran’s status, or other characteristic protected by applicable laws and regulations.
We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.