Senior Mechanical Engineer, Remote Handling and Full Scale Integration

Job Summary

Kairos Power is seeking a highly motivated Senior Mechanical Engineer focused on Remote Handling Special Components with expertise in modular hardware design for remotely operated systems.

This role is centered on the design, physical integration, and demonstration of remote handling technologies through full-scale mockups and prototype builds. The Senior Engineer will drive 1:1 scale integration efforts to validate interfaces, clearances, tolerances, and handling sequences—systematically derisking reactor maintenance strategies prior to deployment.

This position integrates remote handling requirements directly into component architecture and system interfaces to enable efficient assembly, maintenance, inspection, and long-term operability. The role emphasizes hands-on engineering, rapid build-test cycles, and cross-functional collaboration in a highly regulated environment.

Responsibilities

Modular Maintenance System Development

• Apply lifecycle design principles including maintainability, inspectability, and decommissioning
• Integrate remote handling requirements into hardware architecture and system interfaces
• Develop and maintain interface control documentation supporting plant-level integration
• Design, build, and evaluate 1:1 scale mockups and integration test articles to validate handling concepts
• Develop structured test plans and acceptance criteria for full-scale demonstrations
• Coordinate test readiness reviews with QA and Systems Engineering
• Implement design updates based on mockup results, demonstrations, and operational feedback
• Support project planning and cost estimation for integration and testing activities
• Interface with vendors to ensure manufacturability and feasibility of specialized components
• Conduct risk and reliability assessments for maintenance systems
• Ensure compliance with nuclear regulations, safety standards, and applicable codes
• Maintain configuration-controlled design documentation

Remote Handling Solutions

• Develop remote handling hardware enabling efficient component repair and replacement
• Lead hands-on design-build-test cycles to mature handling approaches
• Execute full-scale integration mockups to validate reach, clearances, tooling alignment, ergonomics, and sequencing
• Collaborate with reactor systems and operations teams to define online and offline maintenance strategies
• Identify integration risks early and mitigate through rapid prototyping and physical demonstration

Testing and Validation

• Align demonstration opportunities with reactor and facility schedules
• Develop execution plans for rapid, high-value physical demonstrations
• Support inspections, installations, shakedown, tuning, and commissioning activities
• Capture lessons learned from mockups and integration testing to inform future designs

Collaboration

• Partner with engineering, laboratory, shop, and materials teams to execute accelerated hardware development
• Coordinate cross-disciplinary integration efforts to ensure cohesive system performance

Engineering Reports

• Publish engineering reports documenting design details, mockup results, and integration findings
• Contribute to design basis documentation and regulatory submittals

Team Contribution

• Share technical knowledge and best practices across the organization
• Mentor junior engineers in hardware design, integration, and prototype testing

Other duties as assigned

Qualifications

• B.S. in Mechanical Engineering or equivalent
• 8+ years of experience developing hardware for demanding applications
• Demonstrated experience with full-scale prototypes, physical integration, and hardware demonstrations
• Experience integrating mechanical and electrical systems for remote operation preferred
• Experience in nuclear, aerospace, defense, or other regulated industries preferred
• Molten salt or advanced reactor experience a plus
• Background in low-voltage systems, optical systems, and compact packaging
• Experience with servos, motors, electromagnets, or related power electronics
• Working knowledge of ASME codes and piping standards preferred
• Familiarity with data acquisition tools (LabVIEW, MATLAB, Python) a plus
• Experience mentoring junior engineers preferred

Knowledge, Skills & Abilities

• Expertise in high-temperature systems
• Strong hands-on mechanical aptitude in laboratory and shop environments
• Experience developing physical mockups and rapid prototypes
• Familiarity with radiation effects and material degradation in extreme environments preferred
• Knowledge of pressure and fluid systems
• Familiarity with non-destructive inspection techniques
• Strong written, verbal, and presentation skills
• Ability to collaborate effectively in multidisciplinary teams
• Practical, test-driven problem-solving approach
• Commitment to safety and operational rigor

Physical Conditions 

• Ascending or descending ladders, stairs, scaffolding, lifts, and similar equipment
• Setting up and transferring temporary structures (e.g., scaffolding, ladders)
• Working in tight or confined spaces
• Remaining stationary for prolonged periods (standing or sitting)
• Moving between worksites
• Adjusting, transporting, or installing objects up to 30 pounds
• Use of various hand tools
• Communicating effectively with team members

Environmental Conditions

• General office environment
• Assessing the accuracy, neatness, and thoroughness of the work assigned
• High-concentration, demanding, and fast-paced
• Noisy environments
• Small and/or enclosed spaces
• Elevated heights

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
• Manipulating, cleaning, and disposal of hazardous materials

Travel 

• Some travel may be required, up to 25% 

Additional Requirements

• Requires occasional schedule flexibility
• Requires occasional extended hours to support launch and critical project timelines