Senior Materials Engineer, Material Health Monitoring

What You Will Be Doing:

We are looking for a Senior Materials Engineer to lead the development of materials health monitoring for Helion’s fusion generators. You will design, qualify, and deploy in-situ and ex-situ diagnostics to detect and quantify materials degradation under combined stimuli, including thermomechanical stress, radiation, high electric fields, and coolant environments.

You will work cross-functionally with Materials, Research, and Engineering teams to translate failure modes into measurable signals and integrate diagnostics into hardware and predictive models. You will report to the Lead Materials Scientist, and this is an onsite role located at our Everett, WA office.

You Will:

• Develop and deploy in-situ and ex-situ diagnostics for degradation and failure in fusion-relevant materials and components (e.g., first wall, magnets, insulators, capacitors, HV interfaces, seals)

• Translate failure and degradation modes into measurable signals using sensors, inspection methods, or indirect indicators

• Design and execute coupled-stimuli experiments and post-irradiation examinations (PIE) to validate diagnostic methods

• Manage the roadmap for sensing technologies crucial for structural health monitoring in fusion generator systems

• Build test matrices and analysis plans linking microstructural evolution to sensor outputs and component performance

• Own the materials diagnostics roadmap by converting risk assessments into diagnostic requirements (what to measure, where, how often, and accuracy)

• Collaborate with design engineers to embed diagnostics into hardware and ensure compatibility with system constraints

• Partner with modeling teams to integrate diagnostic outputs into predictive models and maintenance strategies

• Productize diagnostic methods and sensors for reliable deployment in fusion environments

• Document test plans, procedures, and design guidance; communicate results, risks, and recommendations across teams

Required Skills:

• BS with 10+ years, or MS/PhD with 5+ years, in Materials Science, Materials Engineering, Applied Physics, Nuclear Engineering, or related field

• 5+ years (with PhD or MS) or 10+ years (with BS) of experience in at least one of:

  • Materials diagnostics / NDE / SHM (strain, acoustic, optical, EM, fiberoptic, etc.).

  • Familiarity with data analysis / feature extraction for degradation detection (Python preferred).

• Experience designing and executing coupled-stimuli experiments (e.g., thermomechanical, electrothermal, irradiation with stress)

• Experience embedding or integrating sensors into structural materials (ceramics, composites, polymers, or metals)

Preferred Skills:

• Experience in fusion, fission, accelerator, or high-radiation environments

• Experience with radiation effects and post-irradiation examination (PIE)

• Familiarity with high-voltage systems or safety-critical experimental environments

#LI-IB1 #LI-Onsite

• Medical, Dental, and Vision plans for employees and their families

• 10 Paid holidays, plus company-wide winter break

• Up to 5% employer 401(k) match

• Annual wellness stipend