# S3 E9 Scaling Mission-Critical Hardware: Ops Lessons from Space & Fusion with Darby Dunn

- Show: [The Builder Circle](https://hardwarepodcasts.com/podcast/the-builder-circle)
- Published: 2026-02-10
- Length: 1h 24m
- Page: https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby
- Listen: https://rss.com/podcasts/thebuildercircle/2538176

## Summary

Darby Dunn, Vice President of Advanced Manufacturing at Commonwealth Fusion Systems (CFS) and former SpaceX leader, discusses scaling mission-critical hardware operations. She details the design and manufacturing of superconducting magnets like the TFMC and CSMC, the strategic decision to insource magnet production while outsourcing the vacuum vessel, and the importance of defining core competencies and key metrics like cost per kilowatt-hour. Dunn also shares lessons on hiring exceptional talent, maintaining safety culture, and the critical 'test as you fly' mantra derived from a valve failure incident at SpaceX.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=0) Introduction: Darby Dunn and CFS Mission
- [3:59](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=239) Superconducting Magnets: TFMC and CSMC
- [8:47](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=527) Insourcing vs. Outsourcing Core Competencies
- [18:33](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=1113) Hiring Strategy and Cultural Fit
- [17:17](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=1037) Operations in Hardware Development Lifecycle
- [51:13](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=3073) Hardware Horror Story: Dragon Valve Failure
- [1:03:02](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=3782) Scaling Culture and Organizational Structure
- [1:14:10](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=4450) ERP Systems: Custom vs. Out-of-the-Box
- [1:20:24](https://hardwarepodcasts.com/podcast/the-builder-circle/2026-02-10-s3-e9-scaling-mission-critical-hardware-ops-lessons-from-space-fusion-with-darby#t=4824) Advice for Hardware Entrepreneurs

## Topics

- [Scaling production](https://hardwarepodcasts.com/topic/scaling-production)
- [Manufacturing partners & offshoring](https://hardwarepodcasts.com/topic/manufacturing-partners)
- [Hiring & workforce](https://hardwarepodcasts.com/topic/hiring-and-workforce)
- [Leadership, teams & culture](https://hardwarepodcasts.com/topic/leadership-and-culture)
- [Quality & yield](https://hardwarepodcasts.com/topic/quality-and-yield)
- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)

## Most relevant to

companies scaling up

## Mentioned

- Commonwealth Fusion Systems (company)
- SpaceX (company)
- Dragon spacecraft (product)
- TFMC (product)
- CSMC (product)
- Spark (product)
- MIT (company)
- Jiga (tool)

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- [T-25-009 : Sera Evcimen - Mechanical Engineer to Host of The Builder Circle™ Podcast](https://hardwarepodcasts.com/podcast/tradeoffs/2025-10-08-t-25-009-sera-evcimen-mechanical-engineer-to-host-of-the-builder-circletm-podcas) (TRADEOFFS)
- [S7E7 Mike Romance | Industry 4.0, Production Transfers, & People-Centric Leadership](https://hardwarepodcasts.com/podcast/being-an-engineer/2026-02-13-s7e7-mike-romance-industry-4-0-production-transfers-people-centric-leadership) (Being an Engineer)
- [Wait, why is Jeff glowing?](https://hardwarepodcasts.com/podcast/the-amp-hour/2017-10-30-wait-why-is-jeff-glowing) (The Amp Hour)
- [152: Three Main Problems When Scaling a Hardware Startup](https://hardwarepodcasts.com/podcast/product-startup/2022-12-01-152-three-main-problems-when-scaling-a-hardware-startup) (Product Startup)

## Citing this page

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