Senior Manufacturing Engineer – Printed Circuit Heat Exchangers

Responsibilities

• Own PCHE process development from plate fabrication through diffusion bonding, machining, joining, and inspection
• Develop and qualify diffusion bonding parameters to achieve full parent-metal bond integrity
• Author and maintain nuclear-grade manufacturing documentation including travelers, work instructions, and process specifications
• Lead process qualification through design of experiments, coupon testing, metallography, and pressure/leak testing
• Specify tooling and fixtures to improve alignment, dimensional control, and throughput
• Partner with Quality and NDE teams on inspection strategies for bond integrity and dimensional conformance
• Establish SPC monitoring, process control plans, and capability studies for critical characteristics
• Drive root cause analysis and corrective action for nonconformances and scrap
• Provide design-for-manufacturability feedback to design engineering
• Support capital equipment selection and capacity planning for diffusion bonding furnaces and inspection assets
• Mentor junior engineers and establish factory-wide process standards

Requirements

• Bachelor's degree in Mechanical, Materials, Manufacturing, Chemical Engineering, or related discipline
• 5+ years hands-on manufacturing/process engineering experience in precision metal fabrication, heat exchangers, brazing/bonding, or pressure-boundary components
• Deep working knowledge of metal joining processes and associated metallurgy
• Strong command of GD&T, engineering drawings, and dimensional inspection techniques
• Experience qualifying processes through First Article Inspection and production ramp
• Proven root cause and corrective action discipline with data-driven problem solving
• Track record of cross-functional delivery from concept through production handoff

Preferred Qualifications

• Experience in nuclear, aerospace, or highly regulated manufacturing environments (NQA-1, AS9100, ISO standards)
• Direct experience with PCHE, diffusion-bonded, or compact heat exchangers
• Experience with photochemical machining/etching and high-temperature vacuum furnaces
• Familiarity with stainless steels, nickel-base alloys, or high-temperature alloys
• Hands-on ASME BPVC pressure-boundary qualification experience
• Knowledge of SPC, Lean, and Six Sigma methodologies
• Experience integrating manufacturing processes with MES/ERP/PLM platforms

Benefits

• Competitive salary starting at $100,000+
• Health, Dental, and Vision Insurance
• Paid Time Off
• Corporate Gym Membership

About the Company

Aalo Atomics is pioneering factory-fabricated microreactors designed to deliver affordable, scalable, and reliable nuclear power. Based in Austin, TX, the company is working to deploy the world's first fleet of advanced microreactors starting with the Aalo-1, a 10 MWe reactor.