Sr. Process Engineer

Johnson Controls • Burlington, MA

1d • $112,100 - $187,000 • Onsite

About The Position

Sr. Process Engineer, Delivery Cooling performance limits AI infrastructure, semiconductor equipment, photonics, power electronics, defense systems, and other high-powered compute applications. Alloy Enterprises addresses these constraints with advanced thermal management components enabled by its Stack Forging™ process, which creates single-piece, leak-tight metal parts with complex internal microgeometries for stronger cooling performance, lower pressure drop, and high reliability. Founded in 2020, Alloy has built an industry-leading thermal management platform for data centers and mission-critical systems. This role generally requires 4 days onsite per week. As a Sr. Process Engineer, Delivery, you will work on engineering efforts enabling the delivery of high-performance, high-quality parts to Alloy’s customers ahead of schedule. Your primary objective is to provide process expertise throughout production, ensuring that our thermal management solutions meet exacting standards through rigorous process tuning and hands-on problem-solving. You are a resilient, tenacious engineer with a deep sense of ownership. Identifying and dismantling roadblocks is your core competency. You are comfortable navigating a high-growth environment and possess the technical grit and engineering judgment necessary to deliver. You will be the vital link that ensures we deliver successful customer outcomes while pushing the limits of the Stack Forging process.

Requirements

• Education: A Bachelor’s degree in engineering with 5–7 years of professional experience, or a PhD with 3+ years of experience.
• Relevant Experience: Previous work experience with at least one of the following: laser cutting, metallurgy, or statistical data analysis.
• Manufacturing background: Experience with manufacturing methods such as casting, machining, sheet metal forming or brazing
• Hardtech Grit: A proven track record of "making it happen" in complex hardware environments; you have demonstrated resilience and a commitment to getting solutions out the door.
• Communication: Strong ability to articulate technical trade-offs and project status to both internal teams and external customers.
• Tooling: Familiar with CAD (preferably Onshape), and proficiency with Python for data analysis.

Nice To Haves

• Adaptability: Previous experience working in a fast-paced, high-growth environment.
• Mass-Production Experience: Previous experience in a mass-production or high-volume environment.

Responsibilities

• Process Tuning & Optimization: Contribute across the process of Stack Forging, including laser cutting, metal-metal bonding, surface characterization/preparation, complex part geometry design, data and computational analysis, and material property optimization in the support of existing customer projects
• Root Cause Analysis: When things don’t go as expected, you figure out why. You quickly dive deep into the issue, collect critical data, and determine the root cause.
• Hands-On Execution: Your workspace will extend beyond your desk to the Production floor, where you will provide the production team with insight and expertise to ensure high-quality throughput.
• NPI Implementation: Spearhead the integration of new solutions and processes into active customer projects, ensuring they are ready for delivery.
• Feedback Loop: Act as the voice of the production floor for the broader engineering organization, identify long-term process improvements and testing capabilities required for effective delivery.

Benefits

• This role offers a competitive Bonus plan that will take into account individual, group, and corporate performance.
• This position includes a competitive benefits package.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 5,001-10,000 employees