Design Engineer

Major Duties/Responsibilities

* Execute mechanical design and detailing of components and assemblies for fusion-relevant environments, including vacuum-compatible hardware and actively cooled components for high heat-load service.

* Support the full engineering lifecycle: requirements development, concept evaluation, detailed design, fabrication support, assembly/integration, and test/commissioning.

* Develop and maintain engineering drawings, bills of materials, and technical documentation in accordance with applicable engineering standards and ORNL procedures.

* Coordinate with internal shops and external vendors to support manufacturability, procurement, inspection, and quality requirements.

* Support laboratory assembly and integration; perform hands-on troubleshooting of mechanical hardware and interfaces (vacuum systems, water-cooling circuits, RF/mechanical interfaces, instrumentation, and controls interfaces).

* Plan, execute, and document tests to verify component/system performance and resolve technical questions, including thermal and leak/pressure performance where applicable.

* Perform and/or support basic structural and thermal analyses using FEA/CFD tools; validate assumptions and results and communicate findings via technical reports and design reviews.

Provide schedule, cost, and technical status for assigned work; identify risks and propose mitigation actions.

* Collaborate effectively with internal stakeholders and external partners, including other laboratories and domestic/international collaborators, as needed.

Minimum Requirements (Education & Experience)

* BS in Mechanical Engineering, Nuclear Engineering, or a related engineering discipline and relevant engineering experience, or MS in a related discipline with relevant experience.

* Demonstrated ability (through coursework, project work, internships, or professional experience) in: o Mechanical design fundamentals (mechanics of materials; basic thermal response of materials/structures)

o Engineering drawings (creation and checking), GD&T, 3D modeling, component specification, and procurement support

o Fabrication and assembly support for mechanical components/systems

o Designing, executing, and documenting tests

o Reading, understanding, and applying engineering standards and specifications

o Hands-on troubleshooting of mechanical systems and related interfaces (e.g., vacuum and cooling-water systems, instrumentation, controls)

o Basic familiarity with FEA/CFD methods and tools as applied to engineering design (ability to perform simple analyses and report results)

Preferred Qualifications

* Experience with fusion, high-vacuum equipment, magnet systems, RF systems/mechanical interfaces, or other complex research/industrial hardware.

* Experience integrating or assembling complex multi-system devices (mechanical, thermal, fluids, vacuum, RF-adjacent hardware, instrumentation).

* Proficiency or exposure to fluid system design, heat transfer, and facility utilities (cooling water, HVAC, cryogenics, compressed gases).

* Demonstrated ability to work independently, manage multiple tasks, and coordinate with diverse technical teams.

* Strong written and verbal communication skills suitable for technical reporting, design reviews, and interaction with program management and sponsors.

Ability and interest to lead small design or assembly task teams as experience grows.

Key Interfaces/Working Relationships

Works closely with engineers (mechanical, electrical, RF, instrumentation and controls), designers/drafters, technicians, fabrication shops, and project/program management within the Fusion Engineering Group and across ORNL. Interfaces may include external collaborators at other laboratories, universities, and industry partners.

Educational Requirements

BS in Mechanical Engineering, Nuclear Engineering, or a related engineering discipline and relevant engineering experience, or MS in a related discipline with relevant experience.

Experience Level: BS in Mechanical Engineering, Nuclear Engineering, or a related engineering discipline and relevant engineering experience, or MS in a related discipline with relevant experience.