Senior Controls Development Engineer

What You Will Be Doing:  

You will own the development, implementation, and standardization of automation and controls used in manufacturing Helion’s fusion generators. By building in-house expertise in our manufacturing processes, you will help accelerate the transition from rapid prototyping to mass production—advancing Helion’s mission to provide clean electricity for the planet. This is an onsite role that reports directly to the Senior Manager of Manufacturing at our Everett, WA office. 

You Will: 

• Own Helion’s proprietary testing systems and collaborate with stakeholders to develop and improve both existing and new testing processes; work across technical teams to understand product integration within pulsed power circuits to optimize test processes aligned with Helion’s top-level generator goals 
• Design, scale, and launch manufacturing equipment for new products being produced for the first time, including the development of automation system architecture and standards for deployment across multiple production lines 
• Collaborate with machine suppliers on high-level equipment design and functionality; support design reviews, acceptance testing, and equipment buyoff to ensure seamless integration into manufacturing operations 
• Implement safety systems that comply with ANSI, ISO, and OSHA standards for high-volume manufacturing equipment to ensure operational safety and regulatory adherence 
• Produce electrical one-line diagrams and schematics for automated manufacturing equipment; support integration with the factory’s Manufacturing Execution System (MES) and set up equipment reporting to track Overall Equipment Effectiveness (OEE) and other critical machine data 
• Troubleshoot down equipment, identify root causes, and implement long-term solutions to prevent recurrence and ensure sustained manufacturing uptime and efficiency 

Required Skills: 

• Bachelor’s degree in engineering with a minimum of 7 years of experience working with manufacturing controls in high-volume manufacturing environments 
• Proficient in electrical schematic design and PLC programming using ladder logic, function block, or structured text (e.g., Allen-Bradley, Siemens) 
• Experienced in programming industrial robots, including systems such as Fanuc and Kuka 
• Skilled in designing safety systems for automated machines, with relevant experience or qualifications in safety compliance and risk mitigation 
• Ability to apply physics-based first principles to challenge design requirements and underlying assumptions, driving better engineering outcomes 
• Strong communication skills with proven success influencing cross-functional partners and building effective partnerships with supply chain and production teams

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