Senior Aluminum Brazing Engineer

Metheion Technology & Engineering Consulting; Chicago (IL); On-site; USD 120,000 - 160,000; Full time

Job summary

Metheion Technology & Engineering Consulting in Chicago is seeking a hands-on engineer to lead a new aluminum brazing CAB line for EV battery cooling plates. You will define the process, select equipment, and manage procurement to a 10–12 month launch.

The role includes developing brazing parameters, flux choices, furnace profiles, and assembly methods for clad aluminum plates and fins. Once operational, you will monitor process performance, troubleshoot issues, and drive continuous improvement

Qualifications

• Hands-on CAB and continuous belt furnace experience.
• 3+ years of hands-on mechanical or manufacturing design in production.
• Degree in Mechanical Engineering, Manufacturing, Industrial Engineering, or similar.

Responsibilities

• Lead development, installation, and commissioning of a CAB line for high-volume manufacturing.
• Develop and optimize brazing parameters and assembly methods for clad aluminum and fins.
• Define equipment specs and manufacturing requirements to meet throughput and quality goals.
• Manage capital equipment procurement and vendor selection.
• Establish process controls for brazing quality, leak prevention, and flatness.
• Coordinate with coating engineers for downstream compatibility.
• Define SOPs and process documentation for operators.
• Troubleshoot defects, identify root causes, and implement corrective actions.
• Monitor performance and drive yield, scrap and cycle-time improvements.
• Qualify the brazing process through production trials to meet targets.

Skills

CAB expertise

Continuous belt furnace

Aluminum brazing

Mechanical design

Manufacturing experience

ERP/MRP awareness

Education

Bachelor's degree in Mechanical Engineering

Tools

Infor Syteline ERP

Job description

Role description

You will lead the development and launch of a new aluminum brazing process for a production line dedicated to electric vehicle battery cooling plates. You will oversee the full industrialization of the continuous-belt Controlled Atmosphere Brazing (CAB) process, from defining the manufacturing process and selecting the appropriate equipment to managing procurement and commissioning the system.

The production line must be ready for manufacturing within an aggressive 10–12-month timeline. You will develop the brazing process parameters from scratch, including flux selection, brazing profiles, braze paste application, and assembly methods for clad aluminum plates and internal fins. The goal is to establish a stable, repeatable process that consistently meets the quality and throughput requirements of high-volume production. Once the line is operational, you will take on the role of technical expert, monitoring process performance, troubleshooting production issues, improving yield, and driving continuous improvement.

Responsibilities

• Lead the development, installation, and commissioning of a new continuous-belt Controlled Atmosphere Brazing (CAB) production line for high-volume manufacturing.
• Develop and optimize brazing process parameters, including flux selection, furnace thermal profiles, braze paste application, and assembly methods for clad aluminum plates and internal fins.
• Define equipment specifications and manufacturing requirements to meet production throughput, quality, and reliability targets.
• Manage capital equipment acquisition, including Capital Expenditure Requests (CERs), vendor selection, procurement, and equipment acceptance.
• Establish process controls to ensure consistent brazing quality, including leak prevention, corrosion resistance, and component flatness.
• Coordinate with Dielectric Coating Engineers to ensure compatibility between brazing and downstream coating processes.
• Define manufacturing process controls, inspection requirements, and quality documentation required to bring the new brazing line into production.
• Develop and document standard operating procedures and process parameters for production operators.
• Troubleshoot brazing defects and production issues, identify root causes, and implement corrective actions.
• Monitor production performance and drive improvements in yield, scrap rates, cycle times, and equipment uptime.
• Qualify the brazing process through production trials and verify that the line consistently meets product quality and throughput requirements.

Main requirements

• Hands‑on experience with Controlled Atmosphere Brazing (CAB) and continuous belt furnace operations.
• Practical understanding of aluminum brazing principles, including clad materials, fluxes, and filler application.
• 3+ years of hands‑on mechanical or manufacturing design experience in a production setting.

Other requirements

• Degree in Mechanical Engineering, Manufacturing, Industrial Engineering, or similar

Nice to have, but not mandatory

• Experience defining and optimizing furnace thermal profiles for high-volume production.
• Familiarity with post‑braze quality validation, including leak testing and component flatness checks.
• Understanding of pre‑and post‑braze cleaning and surface preparation requirements.
• Previous experience in the automotive, aerospace, or electric vehicle (EV) sectors.
• Experience overseeing large capital equipment purchases, managing vendors, and running equipment run‑offs.
• Familiarity with Enterprise Resource Planning (ERP) or Material Requirements Planning (MRP) software like Infor Syteline or similar.
• Experience with Lean Manufacturing.