Sr. Process Engineer

Department: Engineering

Location: Burlington, MA

Employment Type: FullTime

Cooling performance limits high-power computing, semi-conductor fab, cell networks, photonics, power electronics, and most of our digital world. Alloy Enterprises enables customers to break through these constraints with novel complex metal components that dramatically improve heat dissipation in high-performance systems. Alloy’s patented Stack Forging™ process enables complex micro-geometries, resulting in single-piece, leak-tight parts that deliver superior cooling performance, lower pressure drops, and exceptional reliability. Founded in 2020, Alloy is a 45-person hardtech startup that has raised over $50M in capital and is shipping components to customers manufacturing servers, lasers, semiconductor equipment, and defense systems.

About the role

Alloy Enterprises is seeking a highly motivated and creative Senior Process Engineer to join our Process team and drive the advancement of our novel manufacturing technology. This critical, high-impact role reports to the Director of Process Engineering and Materials.

The successful candidate is a hands-on, creative problem-solver eager to take on complex technical challenges. You will be a key contributor across multiple stages of our manufacturing process, which includes areas such as laser cutting, metal-metal bonding, surface characterization/preparation, complex part geometry design, advanced data and computational analysis, and material property optimization. You will be expected to independently lead projects from initial concept and ideation, through rigorous data collection and analysis, and ultimately to successful handoff to production machines, resulting in parts that go directly to our customers.

This role requires a high degree of technical ownership, cross-functional collaboration, and an ability to thrive in a fast-paced environment. This position generally requires a commitment of 5 days onsite per week.

Responsibilities

*Responsibilities are subject to change based on shifting business needs

• Develop, optimize, and scale the Alloy manufacturing process at all stages to improve quality, throughput, and reliability.

• Lead cross-functional engineering projects by defining scope and priorities, managing technical timelines, and presenting results across the organization.

• Proactively identify and debug complex process issues, brainstorm potential fixes, design and execute experiments to test effectiveness, and implement robust, long-term solutions.

• Work cross-functionally with design, materials, and hardware teams to problem-solve and ensure all design and functional constraints are considered in the process.

• Design and execute formal experiments (DOE), gather and analyze process data, and perform thorough root cause analysis on process failures or performance deviations.

• Assemble and present detailed experimental results and technical findings to both technical and non-technical team members and leadership.

• Design, implement, and maintain inline inspection and data collection systems to monitor and control process stability.

• Develop innovative support removal strategies and post-processing techniques for novel part geometries and advanced materials.

• Write up detailed specifications and requirements for the purchase and commissioning of new laboratory and production equipment.

• Create and maintain comprehensive process documentation, including Standard Operating Procedures (SOPs), for knowledge transfer and production readiness.

• Ideate and champion long-term technical improvements and strategic initiatives that contribute to the next generation of our manufacturing platform.

What you’ll bring

• Technical degree (BS/MS) with 5+ years of industry experience, or a PhD with 2+ years of industry experience, in Materials Science, Mechanical Engineering, Chemical Engineering, or a related field.

• Proven ability to rapidly iterate and improve process methods to significantly enhance throughput, yield, and reliability in a manufacturing environment.

• Deep experience with at least one of the following: imaging processing, in-line inspection and metrology, hardware/instrumentation design and control, machine bring-up and validation, or advanced statistical data analysis.

• Excellent communication skills, both written and verbal, with a demonstrated ability to effectively interpret and present complex technical data.

• A statistically driven mindset for designing experiments, interpreting data, and making data-backed decisions.

• Proficiency with Python software coding in a data analysis and automation context.

• Experience leading technical projects with cross-functional teams that blend hardware, software, and manufacturing development.

• A "get it done" attitude, demonstrating resourcefulness and a drive to find creative solutions to difficult, ambiguous challenges.

• Readiness and enthusiasm to work in a dynamic environment that features: rapidly changing requirements, quick iteration with novel hardware, heavy communication demands, and process development that involves critical, high-risk trade-offs.

• Dynamic and flexible mindset, easily balancing the immediate needs of the day-to-day with long-term strategic thinking and planning.

*The salary range for this role is $115,000-145,000 annually dependent on experience, qualifications, and education level

Additional requirements

This position will require access to information subject to control under U.S. export control laws and regulations, including the Export Administration Regulations (“EAR”) and International Traffic in Arms Regulations (“ITAR”).  Please note that any offer for employment will be conditioned on authorization to receive controlled items without sponsorship for an export license.  

Regarding Sponsorship

Applicants must be authorized to work for any employer in the U.S. We are unable to sponsor or take over sponsorship of an employment Visa, including H-1B, H-1C, H-2A, H-2B, H-3, F-1 or OPT at this time.

Equal employment opportunity

We are committed to creating an equitable and inclusive environment for all our employees and seek to build a team that reflects the diversity of the people we hope to serve with our products. We are proud to be an equal opportunity employer.