FEA Engineer III

Kearny, NJ
Technology – Mechanical 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 highly motivated and experienced Finite Element Analysts to join our rapidly growing team. In this pivotal role, you'll be instrumental in performing complex analysis to design, optimize, and verify the thermal, structural, and magnetic requirements of our cutting-edge stellarator systems. If you have at least 4 years of professional experience and a strong background in mechanical engineering, applied mechanics, materials, and simulation, you'll be well-positioned to deliver insightful results, provide data-driven recommendations, and justify critical design decisions.

Key Responsibility Areas:

  • Owns complex multi-domain and non-linear analyses, defines advanced material/weld modeling parameters, drives structural optimization, and justifies critical design decisions to engineering leadership.
  • Develop and Analyze Complex FE Models: Create complex Finite Element Models, including advanced non-linear contacts, plasticity, and large deformations, to support the design of major stellarator systems and prototyping activities.
  • Perform Multi-Domain Simulations: Develop multi-domain models, including thermal, mechanical, vibration, and magnetic loads.

Ideal Experience & Skillsets:

  • FEA Software Proficiency: 4+ years of industry or academic experience performing Finite Element Analysis using commercial software packages. Experience in scripting and building tools around commercial FEA tools
  • Complex Problem Solving: Demonstrated ability to solve complex engineering problems and identify root causes through meticulous analysis.
  • First-of-its-Kind Development: Proven experience developing first-of-its-kind components or systems.
  • Provides technical guidance and peer-review for junior analysts (Eng I/II) to ensure model accuracy and best practices.
  • Optimize Structural Designs: Utilize various techniques to optimize structures for optimal performance under loading conditions, minimizing weight, and maximizing maintainability.
  • Drive Design Improvements: Actively participate in the design process, identifying opportunities for improvements that lead to higher-performing, lower-cost, and more maintainable systems.
  • Material Modeling: Identify required property development to ensure accurate analysis.
  • Specialized Materials Knowledge: Experience with the cryogenic behavior of materials and welds.
  • Adaptability & Drive: Comfortable working to ambitious timelines with an exceptional work ethic, adaptability, and a continuous improvement mindset.
  • Collaboration & Communication: A strong team player with excellent communication and collaboration skills.
  • Continuous Improvement Mindset: An innate desire to learn, innovate, and critically evaluate ideas, including your own.

Company Benefits:

  • Salary range $120,000 - $155,000
  • Comprehensive health benefits (e.g. medical/dental/vision)
  • Employee equity stock options
  • 20 days PTO
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.