Mechanical Design Engineer

About Zap Energy Zap is advancing the next generation of nuclear power technology across fusion, fission and hybrid applications. Built on an integrated platform of high-energy-density physics and pulsed power, liquid metals and advanced materials, and compact, modular systems, Zap is building the foundational technologies needed to deploy the energy sources of the future.

Mechanical Design Engineer Zap Energy is seeking a Mechanical Design Engineer to support the Zap Modular Reactor (ZMR) program. In this role, you will be part of an integrated project team to deliver a liquid metal cooled fission reactor in support of Zap’s integrated nuclear mission. The ideal candidate is an experienced mechanical designer with strong CAD skills and working knowledge of ASME Codes & Standards, including the Boiler & Pressure Vessel Code (BPVC) Sections VIII and Section III. You will have the opportunity to design components and systems for the high-temperature reactor and liquid metal cooling teams, taking concepts from initial layout through detailed design, fabrication, and installation. This role requires identifying and solving ill-defined first-of-a-kind problems. Being a team player is foundational to success in this role.

Key Responsibilities

Design Ownership: Plan, organize and lead mechanical design efforts within a graded quality program that include: · 3D CAD modeling, assemblies, and detailed drawings (including GD&T) for the ZMR systems and testing platforms. · Skeleton/top-down modeling, interface control, and keeping a reactor-scale assembly stable and traceable. · Selection of codes and standards to which components must be designed and fabricated, including ASME B31.1/B31.3 for piping, ASME Y14.5 for GD&T, AWS D1.1 or AWS/ASME welding standards, ASME VIII and III. · High-temperature design of pressure boundary components and piping to ASME BPVC requirements, in partnership with analysis engineers. · Interfaces between systems (vessel, internals, piping, instrumentation, shielding) and doing interference/clearance checks. · Mechanical design of actuation systems, e.g. reactivity control systems. · Define analysis needs and use FEA results (e.g., ANSYS) and design calculations to drive design iterations.

Individual Contribution: Create and maintain CAD models, drawings, and bills of materials in support of ZMR system development, and perform design-level calculations to size and verify components. Write high-quality documentation with rigor commensurate with the stage of the project and required quality level. Plan work packages to meet schedule milestones. Review and approve engineering deliverables, including supplier submittals and drawings. Cross-Functional Collaboration: Work with analysis, testing, and integration teams to ensure design basis and safety basis are in-sync. Incorporate analysis and test feedback into design iterations, with attention to manufacturability, assembly, and maintainability. Identify and evaluate engineering trade-offs for design basis and safety basis, especially when in conflict. Identify key testing activities to simplify or gain confidence in the design. Actively identify areas for engineering and process improvement, including implementation of solutions. Supplier Collaboration: Act as the technical representative for supplier collaborations, including release of drawings and specifications, fabrication support, and review of manufacturing documentation. Quality Assurance: Perform work within a graded quality assurance program. Identify and implement right-sized solutions to increase efficiency in execution, especially for cross-organizational functions related to quality assurance.

Qualifications

Education: Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Nuclear Engineering or related field from an ABET-accredited program is required. Technical Experience: At least 5 years of experience in mechanical design and delivery of complex systems, including nuclear reactors, flight vehicles, and industrial plants. Preference toward advanced non-water-cooled nuclear reactors. Experience with a PDM/PLM system (Windchill, Teamcenter, SolidWorks PDM, etc.), including revision control, ECO/ECN processes, and release workflows. Technical Skills: Proficient in 3D CAD (e.g., SolidWorks, Creo, NX, or Inventor), including part and assembly modeling, detailed drawings, GD&T, and design for manufacturability. Working knowledge of ASME Codes & Standards, including BPVC Section VIII, applied to mechanical design. Working experience with ASME BPVC Section III Division 5 is a huge plus. Familiarity with FEA tools such as ANSYS to support design iteration. Knowledge of modern software engineering practices and programming languages, such as Python. Communication: Excellent technical writing skills and the ability to clearly present complex information to both internal and external stakeholders, including regulators. Licenses/Certifications: A Professional Engineer (PE) license is preferred.

Personal Attributes and Skills

• Strong commitment to safety, quality, and ethical standards in engineering, including the ability to infuse this commitment throughout the organization.
• Strong problem-solving skills and spatial reasoning with attention to detail.
• Self-starter and can-do attitude.
• Familiarity and competence with basic program management processes and tools.
• Outside the box thinking, grounded in practical engineering solutions.
• Effective communication skills, both verbal and written.
• The ability to collaborate in a multidisciplinary team environment.
• Adaptability, resilience, and commitment to continuous learning.

Employment may be conditioned upon the ability to obtain export authorization. Estimated salary range: $130,000-$190,000 annually. Candidates may be considered for other positions at Zap Energy and actual salary will be based on relevant education, experience, and other qualifications. Range is published in accordance with Washington Equal Pay and Opportunity Act.

Zap Energy is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws and regulations.