Senior Mechanical Engineer, Fuels Program

Job Summary 

Kairos Power is seeking a highly motivated Senior Mechanical Engineer with expertise in the development and implementation of chemical and physical processes stream related equipment, to support the Kairos Power fuels program. In this role, you will work within an engineering team to design, construct, commission and optimize performance of the process equipment necessary for TRISO annular fuel pebble fabrication. You will also work cross-functionally with facility operations, facility engineers, quality assurance, and EHS to enable supporting functions.

Responsibilities

• Design, build and test prototype assemblies to demonstrate functionality and performance under prototypic conditions.
• Lead and participate in design, manufacture, installation, commissioning, and operation of First-of-a-Kind (FOAK) equipment supporting KP Annular Fuel Production Systems.
• Performs and reviews engineering calculations, analyses and design evaluations necessary to substantiate equipment and system designs.
• Monitor equipment performance, recommend and perform design modifications to enhance system reliability based on operational feedback.
• Develop Standard Operating Procedures (SOPs) and maintenance documentation to ensure consistent and safe operations.
• Lead and participate in system integration across mechanical, electrical, controls, and software teams to deliver seamless, high-performing solutions.
• Ensure compliance of all systems with applicable industry codes, safety regulations and site-specific standards..
• Identify opportunities for automation within the Pebble Development Laboratory, implement solutions and measure impact using defined cost-savings metrics.
• Lead investigations into technical issues, perform root cause analyses, implement corrective actions, and support engineering changes and verification processes.
• Leverage internal manufacturing team and management of external vendors to manufacture/procure mechanical and automated systems, applying defined equipment selection criteria and manufacturability analysis.
• Lead and participate in design and safety reviews to validate designs prior to fabrication or implementation.
• Generate and maintain design records, equipment specifications and test reports compliant with internal quality and regulatory standards.
• Manage project timelines, budgets and deliverables for assigned systems or subprojects.
• Train and mentor team members, fostering technical growth and collaboration.
• Perform other duties as assigned.

Qualifications

• Bachelor’s degree in Chemical Engineering, Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or similar discipline.
• 6+ years of relevant engineering experience in a chemical, pharmaceutical, industrial, manufacturing, or comparable process-based setting.
• Experience designing, developing, commissioning, or supporting mechanical or process equipment in an industrial or manufacturing environment.
• Experience in generating Process Flow Diagrams (PFDs), Heat & Material Balances (H&MBs), Piping & Instrumentation Diagrams (P&IDs), equipment lists, and utility consumption lists.
• Experience working with hazardous processes and chemicals, including the implementation of appropriate safety controls.
• Experience in commissioning new vendor supplied equipment, as well as being able to commission in-house designed equipment.
• Mechatronics or electromechanical experience is desirable.
• Hands-on experience with process automation systems (e.g., PLCs, DCS, or SCADA systems) is desirable.

Knowledge, Skills & Abilities

• Proficient with engineering software programs including CAD, SolidWorks and modeling software.
• Team player with excellent verbal, written communication/presentation and interpersonal skills.
• Ability to work with highly collaborative teams.
• Ability to identify opportunities for improvement of existing equipment.
• Ability to verify process designs against mechanical designs, in keeping with operational and maintenance interfaces to ensure that systems and facility are optimal from an installation, integration, operational and maintenance perspective.
• Ability to apply engineering judgment to evaluate equipment and system designs for reliability, manufacturability, maintainability, operability, and performance.
• Ability to troubleshoot complex equipment and process-system issues, conduct root cause analysis and develop effective corrective actions.
• Ability to coordinate mechanical systems with electrical, controls, instrumentation, and automation interfaces in multidisciplinary engineering environments.
• Familiar with process documentation, including PFDs and P&IDs, and how they inform industrial system operations and integration.
• Strong problem-solving and organizational skills, able to manage multiple priorities in dynamic environments while maintaining attention to detail.
• Excellent written and verbal communication skills, with the ability to clearly document plans and effectively convey information across engineering, operations and leadership teams.
• Ability to be proactive and adaptable.
• Prioritizes and ensures safety of oneself and others.
• Ability to proactively collect, manage and transfer knowledge.
• Ability to seek different and novel ways to create efficiencies when working on problems, challenges and issues.

Physical Conditions

• Ascending or descending ladders, stairs, scaffolding, ramps, scissor lifts, articulated boom lifts and the like.
• Moving self in different positions to accomplish tasks in various environments including tight and confined spaces.
• Remaining in a stationary position, often standing or sitting for prolonged periods.
• Moving about to accomplish tasks or moving from one worksite to another.
• Adjusting, moving, transporting, installing, positioning, or removing objects up to 10 pounds in all directions.
• Communicating with others to exchange information.
• Use hand tools.

Environmental Conditions

• General office environment.
• Noisy environments.
• Odors or fumes from chemicals or chemical reactions.
• Assessing the accuracy, neatness and thoroughness of the work assigned.
• High-concentration, demanding and fast-paced.
• Prototyping/Testing environment.
• Manufacturing/Industrial Environment.
• Radiological or Controlled Environment.

Safety and PPE

• Reading and interpreting hazardous warning signs.
• Reporting issues with equipment or unsafe conditions.
• Wearing proper PPE, to include face mask, face shields, gloves, safety shoes, etc.
• Handling of radiological materials.

Travel

• Some travel may be required <5%

Additional Requirements  

• Occasionally requires schedule flexibility.
• Requires extended hours to support launch and critical project timelines (occasionally).

• Onsite: #LI-Onsite