Senior Mechanical Engineer - Machine Design

About the role: 

As the Senior Mechanical Engineer embedded in the Fuel Handling System (FHS) team, you will own how the FHS hardware actually gets made—from one-off test rigs and immersion casks to the production machine that ships to the reactor site. You will be full-time on the FHS team, working shoulder-to-shoulder with the design, test, and controls engineers in our Austin factory. 

You will own the producibility of every part of the system: welded structures, precision-machined components, sheet metal and bent structures, sealing surfaces, shielding assemblies, and sodium-compatible hardware. You will make the call on what gets built in-house versus sourced, drive vendor relationships when needed, and own the metrology plan for the parts that matter. 

We are looking for an experienced manufacturing engineer who can both turn wrenches and direct fabrication—someone who has personally welded, machined, or assembled hardware in a previous role and now leads the producibility of complex systems. This role is highly hands-on and reports into the FHS team while collaborating closely with the broader Austin manufacturing organization. 

Responsibilities: 

• Own producibility for FHS hardware from concept through production: welded structures, machined components, sheet metal/bent parts, shielding assemblies, and sealing interfaces 

• Partner with the design engineers from early concept to ensure designs are buildable, testable, and inspectable 

• Drive in-house fabrication of test rigs, sodium immersion casks, peripheral test equipment, and the full-scale prototype 

• Make and document the in-house vs. outsource decision for each subassembly; manage outside vendors when used 

• Develop weld procedures, tooling, fixtures, and inspection plans for stainless steel and other sodium-service materials 

• Drive process improvements that reduce build time and increase first-pass yield on iterative test hardware 

• Coordinate directly with welders, machinists, and assembly technicians on the factory floor 

• Support on-site installation and commissioning at the reactor facility in Idaho, with periodic travel 

• Champion nuclear quality and safety culture and ensure processes comply with the Aalo Quality Manual. 

Basic Qualifications: 

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or related field 

• 6+ years of manufacturing engineering experience on complex mechanical hardware 

• Deep hands-on knowledge across multiple of: welding, machining, sheet metal forming/bending, assembly, and metrology 

• Demonstrated ability to lead cross-functional teams and mentor junior engineers 

• Proven track record of taking parts from drawing through reliable production 

• Comfortable working hands-on in a fast-paced factory environment 

• Strong ownership mindset and comfort with ambiguity 

Preferred Experience: 

• Stainless steel welding experience (TIG/GTAW), especially for high-purity, vacuum, or sodium-service hardware 

• Experience with CNC machining of complex parts and tight-tolerance assemblies 

• CWI, CWE, or similar weld inspection certification 

• Experience with GD&T and inspection equipment (CMM, laser tracker, optical comparator) 

• Background in nuclear, aerospace, semiconductor, vacuum, or other high-reliability industries 

• Experience building one-off test hardware and iterating quickly 

• Hands-on shop background (e.g., journeyman machinist or welder who moved into engineering) 

Physical: 

• Comfortable working on the factory floor alongside welders, machinists, and assembly technicians 

• Ability to lift up to 25 lbs and stand for extended periods 

• Willingness to perform hands-on fabrication and assembly work 

Requirements

Must be based in the United States

Must be willing to work on-site at our headquarters in Austin, Texas

What It Takes to Succeed at Aalo

We're building technology that will help reshape the future of energy. The pace is fast, the problems are difficult, and the expectations are high. Successful team members consistently demonstrate:

Extreme Ownership — You take responsibility for outcomes, not just tasks. You proactively identify problems, drive solutions, and follow through.

A Passion for Solving Hard Problems — You are energized by challenges that others avoid and enjoy finding practical solutions to complex technical issues.

A Sense of Urgency — You move quickly, make thoughtful decisions, and maintain momentum while balancing quality and execution.

What We Offer

Competitive salary starting at $140,000

Health, Dental, and Vision Insurance

Paid Time Off

Corporate Gym Membership

Candidates only. No recruiters or agencies, please.

Additional Information: 

Aalo 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.