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
This Senior Mechanical Engineer will work within the Advanced Manufacturing team by designing, commissioning, and improving Alloy’s roll-fed inkjet printing and laser-cutting machine. The role will report to the Head of Advanced Manufacturing.
If you're right for this role, you’re a skilled mechanical engineer with expertise in machine design and a deep understanding of reliability and safety. You have experience developing complex machines from concept to execution, solving tough engineering challenges along the way. You take full ownership of your projects, driving them forward independently while maintaining a strong sense of urgency. You know when to pivot, prioritize, and adapt to shifting demands to keep progress on track.
Responsibilities:
Contribute to the design of the machines in Alloy’s manufacturing system, including
Automated equipment for material preparation, printing, cutting, inspection, and assembly
Custom-designed bonding machines
Run design processes with requirements, specifications, concept generation, concept down-selection, and design reviews
Document and communicate design process and decisions
Drive improvement of overall equipment efficiency, manufacturing tolerance, process stability, process monitoring, machine reliability, and automation
Refine and revisit machine requirements with cross-functional teams from product, process, applications, and operations.
Proof-of-concept calculations and benchtop testing to inform design decisions
System and sub-system level design and analysis; utilizing parametric modeling to evaluate trade-offs
Own & update subsystem designs, BOM, specifications, CAD models, and drawings
Select and manage external vendors for components and subsystems
Statistical analysis for assembly tolerance stack up and perform root-cause analyses
Mentor early-in-career engineers
Requirements:
Background in electro-mechanical systems and/or precision machine design
Comfortable in a fast-paced startup environment with a bias towards action
Sound fundamentals and industrial best practices for robust equipment design for production or serially manufactured machinery
Familiarity with design for manufacturing, including sheet metal, machined and welded parts.
Exposure to a variety of automation systems, control cabinets, industrial sensors, PLCs, data acquisition and I/O devices. Experience with GD&T, SolidWorks(with PDM), and FMEA
5+ years industry experience and a 4-year degree in Engineering
Familiar with metal additive manufacturing, robotics, or industrial automation
Experience with rapid prototyping: 3D printing, mill, lathe, laser cutting, CNC, hand tools
Basic SW experience is always helpful: Python, linux, or PLC programming
Experience with any of the following sub-disciplines is a plus: fluid and gas handling, motion planning and control, hydraulics, laser cutting, and vacuum systems
Ability to learn new skills and capabilities on the job
*Pay Range: $125,000-135,000 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.
Top Skills
What We Do
Alloy Enterprises is transforming how aluminum parts are made. Aluminum will be part of the electrification journey of everything that moves, and flexible, on-demand, and cost-competitive fabrication will be essential to this transition. Automotive, aerospace, and industrial equipment need to be lighter, and fabrication methods need to keep pace with the speed of innovative new designs. Our novel, scalable, full-stack additive manufacturing process disrupts the multi-year lead time, process limitations, and high up-front cost of aluminum casting.
“Alloy Enterprises is fundamentally transforming aluminum manufacturing for transportation, much like Carnegie Steel did for the railroad 100 years ago. Now is the time for us to bring scalable additive aluminum manufacturing to mass production and accelerate our society’s ability to electrify everything that moves.” - Alison Forsyth, CEO
Founded in early 2020, the company has raised $43M and is generating revenue with our pilot manufacturing facility. For the first time, on-demand fabrication meets the cost and scale of casting in an exploding $102B market – largely driven by electrification. We are now building out our team and production fab facilities to meet customer demand. If you are a sleeve-rolling builder who sets their bar high and enjoys thinking out loud in a collaborative and inclusive working environment, we’d love to hear from you.
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