Staff Modeling and Simulation Engineer
- Location
- Milpitas, CA · On-site
- Job type
- Full-time
- Level
- Lead / Staff
- Experience
- 10+ years
- Education
- Master's degree
- Listed
- 14 days ago
Skills & highlights for this role
- Finite Element Analysis (FEA)
- Computational Fluid Dynamics (CFD)
- Multi-physics simulation
- ANSYS or COMSOL Multiphysics
- Coupled simulation (fluid-structure, thermal-structural, chemical reaction)
- Verification and validation using physical test data
- Structural mechanics
- Thermal management analysis
- Fluid flow dynamics
Also useful
- Mentoring junior engineers
- Cross-functional collaboration
- Design review leadership
- Simulation data management workflows
- Strain gauge, thermal imaging, and flow sensor data correlation
What you'll do
- Execute Simulation and Modeling: Lead advanced Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) for advanced processing equipment
- Run Multi-Physics Analysis: Build, run, and evaluate highly coupled simulations covering structural mechanics, high-temperature thermal management, fluid/gas flow dynamics, and chemical reaction kinetics
- Apply Engineering Best Practices: Implement engineering workflows for simulation data management, mesh convergence criteria, and rigorous verification and validation (V&V) protocols using physical test data
- Drive Design Reviews: Provide analytical leadership during technical design reviews, verifying structural margins, thermal stress distributions, and flow uniformity to guide design choices
- Collaborate & Interface: Partner closely with cross-functional teams, including Mechanical Designers, Electrical Engineers, Materials Scientists, and Chemical Specialists, to translate simulation insights into actionable hardware modifications
- Project Accountability: Own and report on modeling milestones, timelines, and computational resources to stakeholders, ensuring on-time and in-spec delivery
- Mentor Talent: Coach and mentor junior engineering staff on modeling methodologies, simulation accuracy, and the practical application of finite element principles to real-world hardware
- Get Things Done: Act with speed to solve critical engineering bottlenecks, validating design optimization paths from concept through prototype deployment
What we’re looking for
- Education: Master's or PhD degree in Mechanical Engineering, Aerospace Engineering, Physics, or a related field with a heavy focus on computational mechanics and multi-physics modeling
- Experience: 10+ years of experience in simulation and predictive analysis of complex R&D systems
- Software Mastery: Advanced, hands-on expert in ANSYS, COMSOL Multi-physics, or equivalent high-end FEA/CFD simulation platforms
- Multi-Disciplinary Analytical Expertise: Proven track record of successfully running coupled simulations (e.g., fluid-structure interaction, thermal-structural behavior, and chemical reaction modeling)
- Empirical Correlation: Ability to bridge the gap between virtual models and the shop floor by validating simulation results against physical test metrics like strain gauge data, thermal imaging, and flow sensors
- Leadership: Demonstrated ability to influence hardware design direction through analytical data and lead cross-functional initiatives in a matrixed environment
Bonus points for
- Standards Knowledge: Familiarity with applying industry codes to simulation-driven design validation
- Motion & Dynamics: Experience running transient dynamic simulations or modeling precision motion systems in extreme thermal environments
Must-have requirements
- Ability to lift up to 25 lbs occasionally
- Perform activities such as stooping, climbing, standing, sitting for extended periods of time
- Willingness to travel or work required nights/weekends/on-call occasionally
- Dedication to safety to mitigate industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics
Additional information
At CFS, we excel in fast-paced environments, driven by our values of integrity, execution, impact, and self-critique. As we grow, we’re eager to bring on mission-driven folks who offer diverse perspectives and fresh ways to tackle challenges.
This role requires compliance with U.S. laws concerning the export of controlled or protected technologies or information (collectively, “Export Control Laws"). Any offer of employment will be contingent on the need for compliance with such Export Control Laws.
About Commonwealth Fusion Systems
Commonwealth Fusion Systems is on a mission to deliver the urgent transition to fusion energy.
Combining decades of research, top talent, and new technologies, we’re designing and building commercially viable fusion power plants. And we're working with policymakers, suppliers, and many others to build the energy industry of the future.
We’re in the best position to make it happen. Since 2018, we’ve raised $4 billion of capital, making us the largest and leading fusion company in the world.
Now we’re looking for more thinkers, doers, builders, and makers to join us. People who’ll bring new perspectives, solve tough problems, and thrive as part of a team.
If that’s you and this role fits, we want to hear from you.
Join the power movement as a Staff Modeling and Simulation Engineer
We’re looking for a Staff Modeling and Simulation Engineer to join our design team to help build next-generation hardware. In this role, you will serve as a lead technical expert for advanced simulations, driving the predictive validation of complex hardware systems.
This role requires a high-level practitioner in multi-physics simulation who can comfortably model complex interactions across thermal, structural, fluid flow, and chemical regimes. If you enjoy solving deeply complex physics problems, applying rigorous modeling standards, and working in a collaborative, fast-paced environment to deliver first-of-a-kind hardware, this is your opportunity to make an impact.
Equal opportunity and legal notices
We value diversity deeply and are proud to be an equal opportunity employer by choice. We consider all qualified applicants equally, regardless of race, color, national origin, ancestry, citizenship status, protected veteran status, religion, physical or mental disability, marital status, sex, sexual orientation, gender identity or expression, age, or any other basis protected by law.
From Commonwealth Fusion Systems's careers page, first listed on Rolev.ai on October 26, 2026. Rolev.ai is not the employer.
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Common questions
Where is the Staff Modeling and Simulation Engineer job at Commonwealth Fusion Systems located?
This Staff Modeling and Simulation Engineer position at Commonwealth Fusion Systems is located in Milpitas, CA (On-site). Always check Commonwealth Fusion Systems's application page for specific state eligibility or relocation policies.
What qualifications are required for Staff Modeling and Simulation Engineer at Commonwealth Fusion Systems?
For the Staff Modeling and Simulation Engineer role, Commonwealth Fusion Systems highlights 10+ years of relevant experience; a master's degree; experience with Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), Multi-physics simulation, ANSYS or COMSOL Multiphysics, Coupled simulation (fluid-structure, thermal-structural, chemical reaction), Verification and validation using physical test data. Rolev.ai can score your existing resume against these requirements and show any skill gaps before you apply.
How do I apply for the Staff Modeling and Simulation Engineer position at Commonwealth Fusion Systems?
This listing links directly to Commonwealth Fusion Systems's Lever application page. You can apply directly on Commonwealth Fusion Systems's site, or use Rolev.ai to check your resume fit, generate a zero-hallucination tailored resume and cover letter for this posting, and autofill the Lever application form in 1 click with the Rolev.ai Chrome extension. You always review the form and press Submit yourself.