Technician, Engine Assembly

Job Purpose

The Technician, Engine Assembly is responsible for the high-accuracy assembly of Karno linear generator engine modules. This role supports scaling limited-production builds of a next-generation linear power generation platform.

Unlike traditional rotating engines, this role requires exceptional discipline in axial alignment, stack-up control, sealing integrity, and cleanliness, as well as close collaboration with engineering and quality during design maturation, testing, and iteration.

Duties and Responsibilities

Linear Engine & Genset Assembly

• Assemble Karno linear engine subassemblies, including:
  
  
  
  • Reactor, Heater and Chillers
  • Seal systems (dynamic, static, high-temperature, and gas sealing)
  • Linear generator interfaces (stator/translator interfaces, housings)
  • Structural frames and alignment-critical assemblies
  
  
  
  
• Perform axial and concentric alignment of linear components to tight tolerances.
• Execute precision stack-up controlled assemblies where tolerance accumulation directly impacts efficiency and reliability.
• Apply torque, preload, and fastening sequences per controlled build instructions.

Sealing, Cleanliness & Handling

• Install and verify critical sealing interfaces supporting:
  
  
  
  • High-pressure, high-heat environments
  • Thermal cycling and dynamic motion
  
  
  
  
• Maintain engine-grade cleanliness standards, including:
  
  
  
  • FOD prevention
  • Proper lubrication and material handling
  • Protection of sealing surfaces and linear bearing interfaces
  
  
  
  

Quality & Process Compliance

• Follow detailed work instructions, engineering drawings, torque tables, and build travelers.
• Perform in-process inspections and document critical characteristics.
• Ensure part serialization and traceability for engine-critical components.
• Identify, document, and escalate:
  
  
  
  • Fitment issues
  • Stack-up or alignment risks
  • Seal integrity or assembly-induced failure risks
  
  
  
  

Test, Teardown & Iteration Support

• Support pre-test mechanical verification, leak checks, and readiness reviews.
• Assist with post-test teardown, inspection, and failure analysis.
• Rebuild and reconfigure engines based on test feedback and engineering changes.
• Work closely with manufacturing and design engineers to refine assembly sequences and tooling.

Continuous Improvement & Scale-Up

• Provide hands-on feedback to improve:
  
  
  
  • Assembly methods
  • Tooling and fixtures
  • Error-proofing and standard work
  
  
  
  
• Support PFMEA actions, pilot build readiness, and transition toward limited production.
• Participate in safety, quality, and lean manufacturing initiatives.

Additional duties and responsibilities as assigned, needed, or required for the business.

Qualifications

Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Qualifications include:

• Education, Experience and Certifications
  
  
  
  • High school diploma or GED required
  • Technical certification, military technical training, or trade school preferred
  • 3-7 years of precision mechanical assembly experience, ideally in:
    
    
    
    • Advanced engine or power systems
    • Aerospace or pressure systems
    • Prototype or pilot manufacturing environments
    • High-tolerance electromechanical assemblies
    
    
    
    
  • Experience with:
    
    
    
    • Seal installation and verification
    • Press fits and interference fits
    • Torque and preload-controlled fastening
    
    
    
    
  • Experience with free-piston, linear motors/generators, or non-rotating engine architectures preferred
  • Background in pressure vessels, combustion systems, or high-temperature assemblies preferred
  • Familiarity with prototype test cycles and teardown-driven learning preferred
  • Experience working under ISO 9001 / AS9100-style quality systems preferred
  • Exposure to electromechanical integration (mechanical + stator/translator interfaces) preferred
  
  
  
  
• Skills and Abilities
  
  
  
  • Strong mechanical aptitude with emphasis on linear motion systems
  • Proficiency with precision measurement tools:
    
    
    
    • Micrometers, bore gauges, calipers, dial indicators
    • Feeler gauges and alignment tools
    
    
    
    
  • Ability to read and interpret engineering drawings, GD&T, and assembly schematics
    
    
    
    • Comfortable working with build documentation, travelers, and MES systems
    
    
    
    
  • Extreme attention to detail and precision
  • Discipline in controlled assembly processes
  • Strong mechanical intuition and problem-solving skills
  • Comfort working in evolving designs and pilot environments
  • Ownership of build quality and engine performance outcomes
  
  
  
  

Role Classification and Working Conditions

This is an hourly, non-exempt-level position. This position typically works in a production/assembly/engineering lab environment. Overtime may be required.

Physical/Other Requirements

• Ability to lift and/or move up to 50 pounds.
• Fine motor control and precision hand work for extended periods.
• Ability to travel, as needed, by plane, automobile, etc.