Senior Test Engineer

What You Will Be Doing:

As a Test Engineer at Helion, you will be responsible for designing, building, and sustaining the electrical test systems that validate PCBAs, power electronics, and high-voltage assemblies used across our fusion generators. You will operate at the intersection of design engineering and production, ensuring that test infrastructure is robust, repeatable, and safe for hand-on execution by technicians.

Your work will directly enable faster hardware iteration, improved first-pass yield, and reliable delivery of mission-critical electrical systems that support Helion's fusion generators and pulsed-power architecture. This is a hands-on, lab-based role reporting to the Production Manager and working closely with Design Engineers, R&D Engineers, and Technicians/Supervisors. This is onsite role located at our Everett, WA office.

You Will:

• Design and deliver electrical test systems for PCBA and high-voltage assemblies, including test rack architecture, fixture design, instrumentation selection, electrical integration, and supporting automation

• Design test fixture PCBAs used within test racks and fixturing, owning schematic capture, layout, review, and bring-up to enable functional validation and diagnostics of production hardware

• Build, wire, debug, and maintain complete test racks and fixtures, including power distribution, safety interlocks, signal routing, and data acquisition integration

• Develop and maintain data acquisition and control tools using Python or PLC-based systems to support sequencing, measurement, and reporting

• Write and maintain test procedures, calibration standards, and test limits in collaboration with design engineering and production leadership

• Analyze test data to generate FPY, yield, and performance metrics, and partner with design teams to refine thresholds and improve robustness

• Work hands-on with technicians and supervisors to standardize safe, repeatable test execution and continuously improve test system scalability and maintainability

• Support deployment and sustainment of test infrastructure at Contract Manufacturers, including validation of test hardware and associated electronics

Required Skills:

• Bachelor’s degree in electrical engineering, Mechatronics, or a related field

• 5+ years of experience developing and supporting electrical or electronic test systems in R&D or production environments

• Demonstrated experience designing PCBAs for test fixtures or test systems, including schematic capture, layout, review, and bring-up

• Proficiency with ECAD tools such as Altium Designer or equivalent

• Strong hands-on experience designing, building, wiring, and debugging test racks, fixtures, harnesses, and control systems

• Working experience with Python or PLC-based systems for test sequencing, automation, and data acquisition

• Proficiency using standard lab instrumentation including oscilloscopes, DMMs, power supplies, electronic loads, and spectrum analyzers

• Strong understanding of electrical safety principles and lab best practices

• Strong analytical skills with experience interpreting FPY, yield, or performance metrics

• Proven ability to collaborate across design engineering, production, and technician teams and communicate clearly at multiple levels

#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