Senior Controls Development Engineer

About the role

As a Senior Controls & Robotics Engineer at Aalo Atomics, you will design and build the automated and semi-automated manufacturing lines that produce our modular nuclear reactors. You will architect control systems from the ground up, program PLCs and HMIs, integrate robotic cells and motion systems, and commission production equipment on the factory floor. This is a senior technical role responsible for defining Aalo's factory automation strategy and delivering production-ready manufacturing systems from concept through high-rate operation.

Responsibilities

• Design and architect PLC/HMI-based control systems for automated and semi-automated manufacturing lines (welding, machining, assembly, material handling, inspection)
• Develop and program PLC logic (Rockwell/Allen-Bradley, Siemens, Beckhoff, or similar), HMI screens, and SCADA systems
• Specify and select instrumentation, sensors, actuators, drives, motion control systems, safety devices, and industrial networking hardware
• Integrate robotic systems (articulated arms, cobots, gantries) into manufacturing cells with appropriate safety protocols.
• Commission and validate production equipment on the factory floor — from FAT/SAT through full production handoff
• Develop system functional specifications, control narratives, I/O lists, network architecture drawings, and panel design packages
• Implement industrial communication networks (EtherNet/IP, EtherCAT, PROFINET, OPC-UA, MQTT, Modbus)
• Design safety systems in compliance with relevant machine safety standards (NFPA 79, ISO 13849, IEC 62443)
• Collaborate with MES/IT teams on data acquisition, recipe management, and production traceability systems
• Drive schedule and throughput on automation equipment — identify risks early, solve problems fast, and keep commissioning milestones on track
• Develop and document standards in the factory for robot programming, PLC/Robot communications, safety systems, wiring and pneumatics.
• Troubleshoot complex electromechanical systems and drive root cause analysis for production issues
• Mentor junior controls engineers and technicians; establish controls standards and templates for factory-wide deployment and maintenance

Basic Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, or related discipline
• 7+ years of hands-on experience in industrial controls engineering, automation, or robotics integration
• Expert-level PLC programming (Structured Text, Ladder Logic, Function Block) and/or IPCs on at least one major platform (Rockwell, Siemens, or Beckhoff)
• Experience with HMI/SCADA development (FactoryTalk, Ignition, TIA Portal, or similar)
• Hands-on experience commissioning automated production equipment through FAT/SAT and production ramp
• Solid understanding of servo/motion control and industrial robotics integration
• Experience executing safety risk assessments for automated processes and build-in safeguards that minimize risks
• Experience successfully working cross functionally to deliver automation systems from concept through production handoff

Preferred Experience

• Experience in nuclear, aerospace, defense, or other highly regulated manufacturing environments (eg. NQA-1, AS9100, ISO13485, IS9001)
• Experience integrating controls with MES/ERP platforms
• Experience with IPCs for use in automation and control
• Background in automated welding systems (orbital TIG, electron beam, laser)
• Experience in a greenfield or major capital-project factory buildout
• Knowledge of IEC 61131-3 programming best practices and ISA-88 batch standards

TÜV Functional Safety Engineer (FSEng) or CFSE certification

• Experience building controls standards and templates for multi-line factory deployments
• Experience developing tech packages for industrial robots (Kuka, Fanuc, ABB)
• Experience integrating robotics with CNC equipment
• Experience with offline robot programming and virtual commissioning simulations
• Background in routine robot data acquisition and analysis
• Prior experience in a vertically integrated hardware company where engineers build what they design
• Experience writing code (Python, C++, Rust) and ability to utilize AI effectively
• Strong communication skills to convey technical reasoning and mission-critical messaging clearly

Physical Requirements and Work Environment

• Ability to lift up to 50 lbs, stand for extended periods, and work in confined spaces and at heights.
• Frequent bending, kneeling, climbing, and working in various positions
• Use of welding PPE (hood, FR clothing, gloves) and other PPE as required.
• Factory/shop floor environment with exposure to noise, fumes, heat, UV/arc flash, and moving equipment.

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 based on technical level
• Health, Dental, and Vision Insurance
• Paid Time Off
• Corporate Gym Membership

Candidates only. No recruiters or agencies, please.

Additional Information

• 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.

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