Engines Materials & Process - Casting Engineer III

Application close date:

At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight! 

This is a unique role, which will span Materials and Process Engineering and aspects of casting producibility, where you will help drive manufacturable casting designs to improve first-time yields, followed by qualifying the hardware.

• Relocation provided
• Travel expected up to 20% of the time

• Support and provide oversight for design intent related to casting process development and process control at manufacturing sites.

• Influence, establish, and control process envelopes for gating design, shell, mold prep, and melt/pour process steps such that Engineering requirements are met.

• Influence Design for Manufacturability (DFM) such that cast hardware can be produced at rate with minimal rework

• Review casting part drawings, and collaborate with design, analysis, manufacturing on the implementation of design requirements into production.

• Own casting part qualification; collaborate with design, analysis, manufacturing to align on testing scope.

• Complete Materials & Processes Engineering responsibilities on First Article Qualifications, non-conformances, repairs and continuous improvement projects.

• Find opportunities for new or improved material and process development, coordinate test campaigns, provide program updates to Product Team Leads.

• Participate in the development of internal engineering and quality processes to standardize and accelerate material evaluation, implementation, and qualification procedures.

• B.S. or higher degree in Materials Science & Engineering, Chemical Engineering, Mechanical Engineering or related field
• Minimum 5 years process engineering experience with metal casting
• Ability and willingness to work onsite, with up to 20% of the time (or as needed) being in or traveling to Arlington, WA and the balance being in Kent/Renton, WA or Huntsville, AL
• Experience with basic gating/riser design, investment or molding process, melt and cast process
• Metallurgical expertise with material systems used in the aerospace industry, such as Ni-based alloys, Ti-based alloys, oxygen-compatible alloys
• Experience with part and process qualification and developing process controls
• Ability to collect and analyze data and present results in a meaningful format

• Metallurgical understanding of heat treatment and welding for Nickel-based superalloys

• Experience in CAD software, such as CREO or SolidWorks

• Expertise with casting process simulation software (Magmasoft or ProCAST)

• Expertise in statistical process control for wax, shell, cast, and dimensions

• Experience with and knowledge of investment/shell process and slurries.Ability to drive process control and improvements

• Experience with auditing casting and associated processes.  Expertise with driving corrective actions.

• Experience with failure and forensic analysis of aerospace hardware

• Understanding of aerospace quality standards and Quality Management Systems

Base Pay Range for:

Don’t meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.