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Controls Engineer Jobs in Madison, WI (NOW HIRING)

Realta Fusion, Inc.

Lead Fusion Controls Developer

Madison, WI · On-site

$45.50 - $58.25/hr

The Lead Fusion Controls Developer will design, build, and own parts of the control systems and software that operate Realta's suite of fusion devices, post-processing, and simulation tools. This is ...

Realta Fusion Inc.

Lead Fusion Controls Developer

Madison, WI · On-site

$45.50 - $58.25/hr

The Lead Fusion Controls Developer will design, build, and own parts of the control systems and software that operate Realta's suite of fusion devices, post-processing, and simulation tools. This is ...

Mastermold LLC

Automation Engineer

Johnson Creek, WI · On-site

$90 - $120/hr

Controls Automation Engineer | PLC and Robotics Due to advancement, MasterMold is hiring Controls Automation Engineers to program, troubleshoot, and improve the industrial automation systems that ...

BIOFerm

Controls Programmer

Madison, WI · On-site

$67K - $92K/yr

The Controls Programmer is responsible for developing, implementing, and maintaining the automation and control systems that power BIOFerm's renewable energy facilities. This role focuses on PLC, HMI ...

Promega

Automation Engineer Intern, CMC

Madison, WI · On-site

Under the direction of an Automation/Controls Engineer at Promega's small molecule manufacturing facility, this person will obtain hands-on work experience by completing automation projects to ...

Promega

Automation Engineer Intern, CMC

Madison, WI · On-site

Under the direction of an Automation/Controls Engineer at Promega's small molecule manufacturing facility, this person will obtain hands-on work experience by completing automation projects to ...

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All JobsControls Engineer JobsControls Engineer Jobs in Madison, WI

Controls Engineer information

See Madison, WI salary details

$55.4K

$97.3K

$132K

How much do controls engineer jobs pay per year?

As of Aug 21, 2026, the average yearly pay for controls engineer in Madison, WI is $97,310.00, according to ZipRecruiter salary data. Most workers in this role earn between $84,100.00 and $108,800.00 per year, depending on experience, location, and employer.

What does a controls engineer do?

A Controls Engineer designs, develops, and maintains systems that control machinery and processes in industries such as manufacturing, automotive, and energy. They work with automation systems, including programmable logic controllers (PLCs), sensors, actuators, and human-machine interfaces (HMIs) to ensure efficient, safe, and reliable operation. Controls Engineers also troubleshoot and optimize existing systems, implement upgrades, and ensure compliance with safety standards. Their expertise is crucial for improving productivity, reducing downtime, and integrating new technologies into production environments.

What are the key skills and qualifications needed to thrive as a controls engineer, and why are they important?

To thrive as a Controls Engineer, you need a solid background in electrical engineering, automation, and process control, typically supported by a relevant engineering degree. Familiarity with PLC programming, SCADA systems, HMI software, and certifications such as Professional Engineer (PE) or Siemens/Rockwell training are commonly required. Strong problem-solving abilities, attention to detail, and effective communication skills help distinguish top performers in this field. These skills ensure the safe, efficient, and reliable operation of automated systems critical to industrial and manufacturing environments.

What are common challenges faced by controls engineers when working on multidisciplinary project teams?

Controls Engineers frequently collaborate with mechanical, electrical, and software engineers, which can present challenges in aligning design standards, timelines, and communication styles. They must ensure that control systems integrate seamlessly with hardware and software components while also meeting safety and regulatory requirements. Effective communication and adaptability are essential, as Controls Engineers often act as a bridge between technical disciplines to troubleshoot issues and implement solutions efficiently.

What is the difference between Controls Engineer vs Electrical Engineer?

AspectControls EngineerElectrical Engineer
Required CredentialsBachelor's in Electrical, Mechanical, or Controls Engineering; certifications like Certified Control Systems Technician (CCST)Bachelor's in Electrical Engineering; Professional Engineer (PE) license often preferred
Work EnvironmentManufacturing plants, automation facilities, industrial settingsDesign offices, research labs, power plants, industrial sites
Industry UsageAutomation, manufacturing, process controlPower generation, electronics, telecommunications, industrial systems
Common Search/ComparisonControls Engineer vs Electrical Engineer

Controls Engineers focus on designing, developing, and maintaining control systems for automation and manufacturing processes, often working closely with machinery and PLCs. Electrical Engineers have a broader scope, working on electrical systems, power distribution, and electronic devices. While both roles require electrical knowledge and certifications, Controls Engineers specialize more in automation and control systems, whereas Electrical Engineers may work across various electrical disciplines.

More about Controls Engineer jobs

What are the most commonly searched types of Controls Engineer jobs in Madison, WI?

The most popular types of Controls Engineer jobs in Madison, WI are:

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For Controls Engineer jobs in Madison, WI, the most frequently searched job titles are:

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The top searched job categories for Controls Engineer jobs in Madison, WI are:

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Cities near Madison, WI with the most Controls Engineer job openings:

Controls Engineer jobs near you
Infographic showing various Controls Engineer job openings in Madison, WI as of August 2026, with employment types broken down into 89% Full Time, 6% Part Time, and 5% Contract. Highlights an 87% Physical, 5% Hybrid, and 8% Remote job distribution, with an average salary of $97,310 per year, or $46.8 per hour.

Lead Fusion Controls Developer

Realta Fusion, Inc.

Madison, WI • On-site

$45.50 - $58.25/hr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 5 days ago

Job description

The Lead Fusion Controls Developer will design, build, and own parts of the control systems and software that operate Realta's suite of fusion devices, post-processing, and simulation tools. This is a high-impact technical leadership role that influences the full controls stack, from operator interfaces and visualization tools to hardware integration, real-time data acquisition, and automation infrastructure. The ideal candidate brings deep expertise in either front-end controls and human-machine interfaces or back-end controls and hardware integration, along with the curiosity and collaborative instinct to work fluidly across both. You will work shoulder-to-shoulder with physicists, engineers, and technicians to commission and operate first-of-a-kind fusion experiments in a fast-moving environment. This position may be focused on leading efforts in either back-end or front-end controls, or have elements of both.
Realta Fusion is a rapidly growing start-up developing compact magnetic mirror fusion energy systems to address the biggest challenge of our time -tackling global climate change while ensuring a sufficient energy supply for at least ten billion people on (and off) earth. We are building a team with diverse talents dedicated to making fusion energy a real solution to humanity's most pressing problem.
Key Responsibilities
Lead Developer
  • Provide guidance to junior staff.
  • Collaborate within controls team and closely with engineering and physics teams to define control system requirements and prioritize development efforts across active programs.
  • Participate in design reviews, contributing a controls perspective on new hardware, diagnostics, and infrastructure proposals.
  • Champion safe and reliable operation of experimental systems through rigorous controls design, clear alarming, and well-maintained interlock logic.

Front-End Controls and Operator Interfaces
  • Design and develop operator interfaces, control panels, and visualization tools that give the experimental team clear, intuitive command of complex fusion systems.
  • Build and maintain dashboards and display tools for real-time monitoring of plasma, magnet, vacuum, and power system parameters.
  • Develop graphical and data-driven tools to support experimental operations, shot control workflows, and system diagnostics.
  • Collaborate with physicists and device operators to translate experimental needs into clear, functional interface requirements.
  • Integrate simulation and digital twin capabilities with live controls displays to support pre-shot planning and post-shot analysis.

Back-End Controls and Hardware Integration
  • Develop and maintain control system software for integration with hardware including power supplies, magnet systems, diagnostics, and vacuum and gas handling equipment.
  • Design and implement data acquisition pipelines, event-driven control logic, and real-time interlock systems.
  • Build and maintain device drivers, PLC interfaces, and low-level hardware communication layers.
  • Maintain and extend control system frameworks (EPICS, Tango Controls, LabVIEW, or equivalent) across the device fleet.
  • Develop control system architectures that are robust, testable, and maintainable as the device program scales.
  • Develop and maintain data archiving, logging, and query infrastructure for experimental shot data and system telemetry.
  • Design and implement database-backed tools for trending, alarm history, and long-term performance monitoring of fusion device systems.

Cross-Cutting Responsibilities
  • Contribute to commissioning activities for new devices and subsystems, including controls checkout, hardware testing, and operational readiness.
  • Document control system architectures, software designs, and procedures to support operations, onboarding, and regulatory compliance.
  • Support integration of control system data streams with higher-level analysis and visualization pipelines.

Qualifications
Required
  • Advanced degree in physics, electrical engineering, computer science, or a related technical field, with at least seven (7) years practical experience developing controls to support plasma device operations beyond graduate school.
  • Demonstrated experience developing control system software or human-machine interfaces for experimental, accelerator, or industrial systems.
  • Proficiency in one or more of the following: EPICS, SCADA platforms, LabVIEW, or equivalent controls frameworks used in research or industrial environments.
  • Strong programming skills in Python, C++, or a similar language applied to controls, instrumentation, or data acquisition.
  • Experience integrating software with real hardware, including communication with instrumentation over Ethernet, serial, or fieldbus protocols.
  • Ability to work effectively across hardware and software domains, engaging meaningfully with both the physical systems and the code that controls them.
  • Strong written and verbal communication skills, including the ability to document designs and explain technical decisions to mixed audiences.
  • Commitment to safe and disciplined operation of complex experimental systems.

Preferred
  • PhD with a focus in Particle or Plasma Physics and at least ten (10) years combined working experience in academic and industrial or national laboratory setting
  • Experience with EPICS, Channel Access, PV Access, or equivalent distributed control system frameworks, particularly in an accelerator, light source, or fusion context.
  • Experience developing operator interfaces using Ignition, CSS/Phoebus, PyDM, EDM, or similar HMI tools.
  • Familiarity with real-time control systems, hardware interlock design, PLC programming, and/or fielding and programming microcontrollers, FPGAs and GPUs.
  • Experience in a national laboratory, particle accelerator, or plasma physics or fusion environment.
  • Familiarity with digital twin development or the integration of physics simulations with live control systems.
  • Experience working in a startup or other fast-moving, resource-constrained environment with rapidly evolving requirements.

Applicants who do not meet the entire job specification are encouraged to apply.
Compensation and benefits
What we are working on is hard... and hugely important. Realta Fusion is assembling a talented team bound together by a passion to solve humanity's biggest challenge with first-of-a-kind technology. Additionally, Realta offers:
  • Competitive compensation package, including equity stock options
  • Comprehensive benefits including health, dental, and vision insurance, plus a 401(k)
  • Flexible paid time off (PTO) to support work-life balance
  • Work and live in Madison, Wisconsin - one of America's most livable and vibrant cities; hybrid work options may be available for this position, but a weekly on-site presence will be required

We value diversity as a critical factor in innovation and believe a diverse team is necessary to solve the toughest problems. We aim to create an inclusive environment that unleashes the full creativity of our team members from a wide variety of backgrounds and experiences. We provide equal employment opportunities to all individuals based on merit and without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or any other protected status under applicable laws.

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