Senior Mechanical Design Engineer

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! 

As a senior member of the TeraWave propulsion team, you will play a foundational role in the development of the Hall thruster-based propulsion systems that maneuver the TeraWave constellation satellites as well as the propulsion team itself. TeraWave is a satellite communications network designed to deliver symmetrical data speeds of up to 6 Tbps anywhere on Earth. This network will service tens of thousands of enterprise, data center, and government users who require reliable connectivity for critical operations.

As a Senior Mechanical Design Engineer, you will lead the development of the propulsion system mechanical designs. You will work with propulsion team members to create propulsion system and subsystem-level designs informed by product requirements, development test results, and outcomes of design for test/manufacturability/assembly reviews. Successful candidates will utilize their experience in aerospace design to make tactical decisions on scalable team practices and design optimizations for high-rate production as well as use that experience to lead and mentor junior team members. A preferred candidate will have experience in electric propulsion system and subsystem design and manufacturing for production rates including experience designing high-pressure and low-pressure fluid systems, Hall thrusters, power electronics enclosures, system-level and vehicle integration MGSE, and associated test fixturing for environmental acceptance testing.

If you share our passion for propulsion system development and design, thrive in a dynamic startup environment, excel on integrated cross-functional teams, are experienced and skilled in several relevant areas listed below, continuously seek out opportunities to learn and improve, and do not allow title or job description to limit the depth or breadth of your contributions, then we would love to hear from you.

• Relocation provided
• Travel expected up to 15% of the time

• Author propulsion system designs and drawings, iteratively improving those designs from concept to production.
• Lead design reviews and coordinate inputs from thermal, propulsion, structures, test, and manufacturing engineering team members.
• Work closely with other propulsion team members through iterative design, build, test loops to ensure that designs account for product requirements and appropriate DFx (Design for manufacturing/assembly/test/automation/etc.) considerations
• Technical contributions to the growth of the team through assisting in hiring, identifying team skill gaps, and mentoring junior team members.
• Formulate and lead trade studies to improve production efficiency and reduce defects.
• Work with manufacturing and test engineers to design build and test tooling/fixtures.
• Identify, communicate, and mitigate cost, schedule, and technical risks.
• Coordinate closely with thermal and structural functional teams to ensure designs meet environmental flight requirements.
• Coordinate with satellite vehicle integration team members on defining propulsion system interfaces an designing tooling for integration of the propulsion system with the vehicle

• Bachelor of Science in Aerospace, Mechanical Engineering, or related technical subject area.
• 8+ years of career experience in propulsion system development, production, and test.
• Experience working with flight hardware in a production facility, or laboratory.
• Strong mechanical design and integration skills using 3-D CAD software (Creo Pro/E preferred).
• Proficient with application of GD&T (ASME Y14.5) and performing dimensional variation analysis.
• Proven experience and successful track record developing/starting new product designs
• Ability to communicate clearly and appropriately at all levels of the organization.
• Ability to earn trust, maintain positive and professional relationships
• Knowledgeable in aerospace manufacturing practices & tools.
• Ability to read and interpret engineering drawings, engineering industry standards, and technical requirements.
• Ability to perform design analyses and present resulting technical information in a clear and compelling visual format.
• Excellent verbal, written, and graphical communication skills.
• Ability to work collaboratively in a cross-functional, fast-paced, dynamic work environment.
• Enthusiasm for mentoring, training, knowledge sharing, and supporting the technical development of team members.

• Working knowledge of electric propulsion (e.g., ion, Hall-effect) system operating principles and design practices.
• Experience designing complex integrated assemblies such as high and low-pressure fluid systems, high voltage assemblies, high temperature assemblies, electronics enclosures, as well as associated mechanical ground support equipment and tooling for test and vehicle integration.
• Experience with production lifecycle management (PLM) tools (Windchill preferred).
• Experience designing hardware to meet thermal, vibration, shock, and/or vacuum testing requirements on flight hardware in accordance with MIL-STD-810, SMC-S-016, and MIL-STD-1540.

• Electric propulsion production system and/or subsystem design experience (e.g. Hall thrusters, hollow cathodes, feed systems, propellant tanks).
• Experience developing a propulsion system from concept to production through iterative design, build, and test loops.
• Experience designing production hardware and optimizing the design for increasing production rates.
• Excellent computer skills with the ability to quickly learn and use various software tools as needed.
• Experience with automated tooling/robotics (design for automation).
• Experience with AS9100 Quality Management System.
• Expertise with analysis codes: Nastran, ANSYS, Optistruct, LS/Dyna, Abaqus.
• Experience coordinating with vehicle integration on the interface design requirements of a line replaceable unit (LRU) onto a flight vehicle.
• Experience with Optimization and DOE methods as applied to design, analysis, and testing.
• Experience working in a multi-functional team responsible for selecting manufacturing processes, and developing the design to produce extraordinary engineered products.

• Support production floor activities. 
• Climb stairs and work in small areas. 
• Lift and carry 40 lbs.

Compensation 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.