About Aalo AtomicsAalo Atomics is pioneering a new era in clean energy with factory-fabricated microreactors designed to deliver affordable, scalable, and reliable nuclear power. Our mission is to make nuclear energy globally accessible, starting with the Aalo‑1, a 10 MWe reactor leveraging cutting‑edge safety, modularity, and efficiency. Based in Austin, TX, we're rapidly growing as we work to deploy the world's first fleet of advanced microreactors. Join us and help revolutionize energy for a sustainable future.About the RoleAs a Senior Manufacturing Engineer for Printed Circuit Heat Exchangers (PCHEs) at Aalo Atomics, you will own PCHE production from collaborating with design engineering on development and prototyping through to repeatable, qualified manufacturing. You will be the technical authority on the floor for all processes related to PCHE production. This is a senior technical role responsible for defining and maturing Aalo's PCHE manufacturing process from process development and qualification through high‑rate production.Key ResponsibilitiesOwn process development across plate fabrication, cleaning/surface prep, stack‑up, diffusion bonding, post‑bond machining, final joining, and inspectionDevelop and qualify diffusion bonding parameters (temperature, pressure, time, surface preparation) in partnership with materials and process engineering to achieve full parent‑metal bond integrityDevelop and qualify external suppliers and special‑process vendors as needed during prototype and production rampAuthor and maintain travelers, work instructions, routings, and process specifications that meet nuclear‑grade documentation and code requirementsLead process development, qualification, and production validation through design of experiments, coupon testing, bond‑line metallography, dimensional verification, proof/burst testing, and helium leak testingSpecify and develop tooling, fixtures, and inspection methods to improve plate alignment, dimensional control, and throughputPartner with Quality and NDE teams to develop inspection strategies for internal channel geometry, bond integrity, dimensional conformance, and final pressure‑boundary acceptanceEstablish process control plans, capability studies (Cpk), and SPC monitoring for critical‑to‑quality characteristicsDrive root cause analysis and corrective action for nonconformances, scrap, and rework — and turn findings into permanent process improvementsProvide design‑for‑manufacturability (DFM) feedback to design engineeringDrive schedule and throughput on PCHE production — identify risks early, solve problems fast, and keep qualification and production milestones on trackSupport reliability and design‑validation testing including thermal, pressure‑cycle, and environmental testing to establish manufacturing robustness and service readinessSpecify, select, and justify capital equipment for diffusion bonding furnaces, etching, and inspection assets; support capacity and production planningExperience developing controlled processes for pressure‑boundary or safety‑critical hardwareExperience with cleaning, contamination control, and surface preparation for metal joining processesExperience working with external suppliers or special‑process vendors to qualify manufacturing stepsDevelop and document factory standards for etching, bonding, welding, and inspection processesEstablish full material and process traceability, inspection records, and manufacturing data packages required for pressure‑boundary hardware. (ASME BPVC Section VIII, NQA‑1 where applicable)Success in this role means establishing a qualified, repeatable PCHE manufacturing process with clear process windows, controlled documentation, defined inspection methods, and production readiness.Mentor junior manufacturing engineers and technicians; establish process standards and templates for factory‑wide deploymentBasic QualificationsBachelor's degree in Mechanical, Materials, Manufacturing, Chemical Engineering, or related discipline5+ years of hands‑on experience in manufacturing/process engineering in precision metal fabrication, heat exchangers, brazing/bonding, or pressure‑boundary componentsDeep working knowledge of metal joining processes — diffusion bonding, brazing, or welding — and associated metallurgyDemonstrated ownership of manufacturing process documentation, travelers, and process specificationsStrong command of GD&T, engineering drawings, and dimensional inspection techniquesHands‑on experience qualifying production processes through First Article Inspection and production rampExperience executing process qualification and validation (coupon testing, metallography, pressure/leak testing)Proven root cause / corrective action discipline (8D, 5‑Why, fishbone) and data‑driven problem solvingExperience successfully working cross‑functionally to deliver manufacturing processes from concept through production handoffPreferred QualificationsExperience in nuclear, aerospace, defense, or other highly regulated manufacturing environments (e.g., NQA‑1, AS9100, ISO 13485, ISO 9001)Direct experience with PCHE, diffusion‑bonded/compact heat exchangers, or plate‑fin heat exchangersExperience with photochemical machining/etching processesExperience with high‑temperature vacuum or inert‑atmosphere furnacesExperience with HIP, vacuum hot pressing, or similar solid‑state bonding processesFamiliarity with material systems relevant to compact heat exchangers such as stainless steels, nickel‑base alloys, or high‑temperature alloysHands‑on ASME BPVC pressure‑boundary qualification experienceExperience with NDE methods for internal channels and bond lines (RT, UT, CT, dye penetrant, He leak)Experience in a greenfield or significant factory buildoutKnowledge of SPC, Lean, and Six Sigma methodologiesExperience integrating manufacturing processes with MES/ERP/PLM platformsPrior experience in a vertically integrated hardware company where engineers build what they designComfort using data analysis, scripting, and modern AI tools to accelerate process development, documentation, and root‑cause analysis.Strong communication skills to convey technical reasoning and mission‑critical messaging clearlyPhysical Requirements & Work EnvironmentAbility to lift up to 50 lbs, stand for extended periods, and work in confined spaces and at heightsFrequent bending, kneeling, climbing, and working in various positionsUse of PPE as requiredFactory/shop floor environment with exposure to noise, fumes, heat, UV/arc flash, and moving equipment.RequirementsMust be based in the United StatesMust be willing to work on‑site at our headquarters in Austin, TexasWhat It Takes to Succeed at AaloExtreme OwnershipYou take responsibility for outcomes, not just tasks. You proactively identify problems, drive solutions, and follow through.A Passion for Solving Hard ProblemsYou are energized by challenges that others avoid and enjoy finding practical solutions to complex technical issues.A Sense of UrgencyYou move quickly, make thoughtful decisions, and maintain momentum while balancing quality and execution.What We OfferCompetitive salary starting at $100,000+Health, Dental, and Vision InsurancePaid Time OffCorporate Gym MembershipCandidates only. No recruiters or agencies, please.Additional InformationAalo Atomics provides a collaborative and supportive work environment, opportunities for professional growth, intellectually challenging careers, and competitive compensation. Aalo Atomics is an equal opportunity employer and considers all employment decisions without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, veteran status, or any other characteristic protected by law.Applicants must be U.S. Citizens or U.S. Persons in compliance with 10 CFR Part 810 and may not hold non‑compliant foreign citizenships.Direct applicants only. No recruiters or staffing agencies, please.#J-18808-Ljbffr