We are looking for an experienced and highly motivated Emerging Materials & Manufacturing Development (EMMD) Manager to lead the development of novel materials and manufacturing technologies for the STEP programme—helping to deliver the UK’s prototype fusion energy plant and enable future commercial fusion power.
This is a unique opportunity to operate at the cutting edge of materials science, manufacturing engineering, and fusion technology, driving forward first-of-a-kind solutions that will underpin the success of next-generation energy systems.
The Opportunity
In this pivotal technical leadership role, you will define and deliver the strategy for maturing low Technology Readiness Level (TRL) materials, advanced manufacturing techniques, and industrial processes. You will work closely with industry partners, academia, and the Fusion Partner to translate ambitious design requirements into scalable, manufacturable, and qualifiable solutions.
Your work will directly influence technology readiness, design maturity, cost, risk, and plant buildability for both the STEP Prototype Plant and future commercial fusion programmes.
Key Responsibilities
Programme Leadership
- Lead the Emerging Materials & Manufacturing Development programme across critical STEP systems and components
- Define and deliver roadmaps for:
- Novel structural and functional materials
- Advanced joining technologies
- Fabrication and assembly methods
- Inspection and repair approaches
- Align development activities with design maturity, qualification requirements, programme milestones, and supply chain strategies
- Identify and prioritise development activities to mitigate technical and manufacturing risks
Materials Development
- Oversee the development and assessment of advanced materials, including:
- High-temperature structural alloys
- Copper alloys and heat sink materials
- Refractory and plasma-facing materials
- Ceramics, insulators, seals, and ancillary materials
- Lead the generation of material property data and design allowables
- Contribute to the development of a robust and defensible materials database
Manufacturing & Process Development
- Define and mature early-stage manufacturing routes, including:
- Machining, forming, and additive manufacturing
- Powder metallurgy and HIP processes
- Advanced joining (brazing, diffusion bonding, welding)
- Coatings and surface engineering
- Assembly and integration techniques
- Lead process trials, prototype builds, and sub-scale demonstrations
- Establish process windows, critical parameters, and quality requirements
Cross-Functional Leadership
- Act as the organisation’s subject matter expert for emerging materials and manufacturing
- Support design reviews, manufacturing readiness assessments, FMEA, and lifecycle assessments
- Collaborate with engineering, supply chain, and regulatory teams to ensure solutions are scalable, inspectable, and deployable
About You
We are looking for a confident technical leader with a passion for innovation and delivery. You will bring:
- Degree (or equivalent experience) in Materials Science, Manufacturing Engineering, or a related discipline
- Strong experience in advanced materials development and manufacturing process engineering
- Proven track record of delivering low TRL technology development programmes
- Experience working across industry, academia, or large-scale engineering programmes
- Knowledge of qualification methodologies, testing, and materials databases
- Strong leadership and stakeholder management skills
Experience in nuclear, fusion, aerospace, or other highly regulated industries is desirable.
Why Join Us?
- Play a leading role in delivering fusion energy, one of the most transformative technologies of our time
- Work on first-of-a-kind engineering challenges with global impact
- Collaborate with world-leading experts across industry and research
- Competitive salary and benefits package
- Opportunity to shape the future of a growing fusion supply chain
