Deep caramelized onion jam, melted Gruyère, and a yellow mustard smash crust — everything that makes French onion soup great, now on a burger. Make the jam ahead and the rest comes together in five minutes of hot cast iron.
Melt butter in a wide skillet over medium-low heat. Add onions and salt, stir to coat. Cook 45 to 60 minutes, stirring occasionally, until deeply browned, jammy, and reduced. Add Worcestershire and beef broth. Simmer until thick and glossy, 3 to 5 minutes. Finish with black pepper. Set aside or refrigerate up to 3 days.
Make the Thyme Aioli
Whisk together mayo, lemon juice, thyme, and black pepper until smooth. Refrigerate until ready to use, up to 2 days ahead.
Prep the Beef
Divide the ground beef into 4 equal portions and gently press each one into a loose patty, about 4½ to 5 inches wide - don't overwork it. Lightly spread ½ to ¾ teaspoon of yellow mustard on one side of each patty.
Heat the Skillet
Heat cast-iron skillet or flat-top over high heat until screaming hot, 3 to 5 minutes. Lightly oil the surface.
Smash and Sear
Place the patties mustard-side down. Season the top with kosher salt. Cook undisturbed 2 to 3 minutes until a deep mahogany crust forms and releases cleanly. If it sticks, wait 10 to 15 more seconds.
Flip and Melt
Flip each patty, season with black pepper, top with Gruyère. Cover with a dome or lid and cook 60 to 90 seconds until cheese is melted and internal temp reads 160°F.
Toast and Assemble
Toast buns cut-side down in burger fat. Spread aioli on the bottom bun. Layer arugula, patty, then a generous spoonful of onion jam. Top and serve immediately.
Notes
Don't season the beef before forming. Salt breaks down proteins early and causes steaming rather than searing.
Make the onion jam 1 to 3 days ahead. Flavor improves overnight. Reheat it with a splash of water or beef broth to loosen if needed before buulding the burgers - you want the onions warm when you bite into the smash burgers.
Thyme aioli can be made up to 2 days ahead.
The onion jam keeps refrigerated for up to 5 days.
Store components separately. Don't assemble before storing.