Process Engineer
Confirmed on the employer's own hiring board on Nov 2, 2026. First seen by Alion on Oct 30, 2026. Johnson Controls scores B on the Alion truth index.
About Johnson Controls
Johnson Controls, a global leader in thermal management, mission-critical building systems, energy efficiency, and decarbonization, helps customers use energy more productively, reduce carbon emissions, and operate with the precision and resilience required in rapidly expanding industries such as data centers, healthcare, pharmaceuticals, advanced manufacturing, and higher education.
For more than 140 years, Johnson Controls has delivered performance where it really matters. Backed by advanced technology, lifecycle services and an industry-leading field organization, we elevate customer performance, turn goals into real-world results and help move society forward.
Visit johnsoncontrols.com for more information and follow @Johnsoncontrols on social platforms.
What You'll Do
As a Process Engineer on the SFTS Process Engineering team, you will oversee process and asset health related to our laser cutting and bonding processes. Your primary objective is to maintain process stability and aid in improvements to how these machines perform: understanding them deeply, working with the controls that run them, and making them more capable as we scale from development into large-scale manufacturing.
This is a hands-on role that will work closely with other process engineers, controls engineers, engineering technicians, production teams, and quality to implement new laser and bonding capability, solve issues on the operations floor, and bring improvements from idea to production.
Who You Are
You are a process engineer who loves the machine as much as the process. You have hands-on laser experience on the implementation and engineering side, and you enjoy being involved in the design of new systems. This role will require some combination of mechanical, electrical, and computational skills. You come from a laser welding, controls, or additive manufacturing background and understand how materials, process parameters, and equipment behavior combine to drive part quality.
You take ownership of your projects and drive them forward with a strong sense of urgency. You communicate clearly, whether you're presenting a design to engineering leadership, walking a technician through a change, or demonstrating a new capability to production and quality.
This role requires a high degree of technical ownership, cross-functional collaboration, critical thinking for root cause analysis, and an ability to thrive in a fast-paced environment. This position requires a commitment of 5 days onsite at our Burlington, MA, facility. Candidates must be commuting distance to the facility, or able to relocate. Only US Citizens and/or Permanent Residents of the US will be considered.
How you will do it
- Serve as a process and equipment subject matter expert for aspects of the Stack Forging process, including laser cutting and bonding machines. This includes equipment behavior, process variables, and failure modes
- Lead implementation and engineering initiatives related to laser cutting and laser processing capability, from parameter development through qualification and handoff to production
- Work cross functionally to influence the design, build, and improvement of control systems for process equipment, spanning mechanical, electrical, and software elements such as sensors, I/O, PLCs, and control code.
- Work cross functionally to design, implement, and maintain process monitoring, inline inspection, and data collection systems to monitor process stability.
- Proactively identify and debug complex process and equipment issues, design and execute experiments, and implement robust, long-term solutions.
- Perform thorough root cause analysis on parts, processes, and machines.
- Drive improvements in yield, throughput, machine reliability, and repeatability on laser cutting and bonding operations.
- Lead process and equipment projects by defining scope and priorities, managing timelines, and coordinating across teams.
- Communicate, present, and demonstrate ideas, designs, and process changes effectively to technical and non-technical audiences, including leadership.
- Partner with process engineers, control engineers, engineering technicians, production, and quality to roll out changes, including documentation, training, and sustainment.
- Support large-scale manufacturing by owning process documentation and work instructions for your equipment.
What You Will Need
Required
- 4+ years of work experience in a similar field, such as industrial metal 3D printing or additive manufacturing.
- Experience in metals or metallurgy, laser cutting, 3D printing, mechanical engineering, or additive manufacturing.
- Some mechanical, electrical, and coding experience, including familiarity with industrial sensors, control cabinets, PLCs, data acquisition, and I/O devices.
- Demonstrated ability to communicate and present new ideas, designs, or changes effectively across engineering, production, and quality teams.
- Experience working closely with cross-functional teams that blend hardware, software, and manufacturing.
- A statistically driven mindset for designing experiments, interpreting data, and making data-backed decisions.
- US Citizen and/or permanent resident.
Preferred
- Laser welding background, controls or computational background, or a degree in additive manufacturing.
- Project management experience, including defining scope, managing timelines, and driving projects to completion.
- Process design experience and experience supporting large-scale manufacturing.
- Experience with metal-to-metal bonding, joining, or related thermal processes.
- Proficiency with Python, PLC programming, or similar for controls, automation, and data analysis.
About Johnson Controls
Johnson Controls, a global leader in thermal management, mission-critical building systems, energy efficiency, and decarbonization, helps customers use energy more productively, reduce carbon emissions, and operate with the precision and resilience required in rapidly expanding industries such as data centers, healthcare, pharmaceuticals, advanced manufacturing, and higher education.
For more than 140 years, Johnson Controls has delivered performance where it really matters. Backed by advanced technology, lifecycle services and an industry-leading field organization, we elevate customer performance, turn goals into real-world results and help move society forward.
Visit johnsoncontrols.com for more information and follow @Johnsoncontrols on social platforms.
What you will do
Thermal constraints limit AI infrastructure, semiconductor equipment, power electronics, and defense systems. JCI removes those constraints. Enabled by the Stack Forging™ process, JCI produces high-performance thermal components and cooling loop solutions - purpose-built for direct integration into AI, HPC, and mission-critical systems. JCI has built the industry's leading thermal management platform for the applications that demand it most.
As a Builder on the Stack Forging Thermal Solutions team at Johnson Controls, you'll join a team of sleeve-rollers who set a high bar for themselves and their co-workers. We foster a collaborative culture with no silos, where everyone is encouraged to think out loud. If you are passionate about your craft and don't give up until you've found a way, you will make an ideal Builder!
As a Senior Mechanical Engineer, New Product Introduction, you will work on engineering efforts to bring products from the lab into mass production. Your primary objective will be commissioning, and improving the next generation of machines used in the Stack Forging process.
Who You Are
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.
This role requires a high degree of technical ownership, cross-functional collaboration, critical thinking for root cause analysis, and an ability to thrive in a fast-paced environment. This position generally requires a commitment of 4 days onsite per week. This position is located in Burlington, MA. Candidates must be commuting distance to the office, or able to relocate. Various relocation packages are available. Only US Citizens and/or Permanent Residents of the United States will be considered, since sponsorship is not available for this position.
How you will do it
- Component design within the machines in Stack Forging manufacturing system, including automated equipment for material preparation, cutting, inspection, bonding, and assembly
- 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
What you will need
Required
- Bachelor's degree in Mechanical Engineering and 5+ years industry experience
- Sound fundamentals and industrial best practices for robust equipment design for production of serially manufactured machinery
- Exposure to a variety of automation systems, control cabinets, industrial sensors, PLCs, data acquisition and I/O devices.
- Proficiency in thermal analysis of vacuum systems, including radiative heat transfer, thermal gradients, and bakeout planning
- Ability to perform conductance calculations and pump down modeling to optimize system performance
- 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.
Preferred
- Background in electro-mechanical systems and/or precision machine design
- Dynamic and flexible mindset, easily balancing the immediate needs of the day-to-day with long-term strategic thinking and planning.
- Experience with GD&T, SolidWorks (with PDM), and FMEA
- Experience with any of the following sub-disciplines: fluid and gas handling, motion planning and control, hydraulics, laser cutting, and vacuum systems
- Comfortable in a fast-paced startup environment with a bias towards action
- Familiarity with design for manufacturing, including sheet metal, machined and welded parts.
Export Control Requirement: This position may require access to information, technology, technical data, software, or other items subject to U.S. export control laws and regulations. Any offer of employment for this position may be contingent upon the candidate's ability to obtain and maintain any required export authorization or eligibility to access controlled items.
HIRING SALARY RANGE: $70,000 - $90,000 (Salary to be determined by the education, experience, knowledge, skills, and abilities of the applicant, internal equity, and alignment with market data.) This position includes a competitive benefits package. The posted salary range reflects the target compensation for this role. However, we recognize that exceptional candidates may bring unique skills and experiences that exceed the typical profile. If you believe your background warrants consideration beyond the stated range, we encourage you to apply. To support an efficient and fair hiring process, we may use technology assisted tools, including artificial intelligence (AI), to help identify and evaluate candidates. All hiring decisions are ultimately made by human reviewers. For details, please visit the About Us tab on the Johnson Controls Careers site at https://jobs.johnsoncontrols.com/about-us
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Johnson Controls International plc. is an equal employment opportunity and affirmative action employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, age, protected veteran status, genetic information, sexual orientation, gender identity, status as a qualified individual with a disability or any other characteristic protected by law. To view more information about your equal opportunity and non-discrimination rights as a candidate, visitEEO is the Law. If you are an individual with a disability and you require an accommodation during the application process, please visit here.