Senior Manufacturing Engineer - Propulsion

Company Overview

Cowboy Space Corporation is solving the global energy crisis by building the infrastructure for abundant, resilient space‑based solar energy. The company is tackling one of humanity’s most complex engineering challenges with a world‑class team dedicated to delivering a revolutionary power platform. Cowboy Space’s modular, scalable satellites collect sunlight in Low Earth Orbit to enable multiple integrated applications: transmitting energy via infrared lasers (space‑to‑earth and space‑to‑space), powering on‑orbit high‑performance computing clusters (GPU/TPU), and providing secure, high‑bandwidth optical data transport. The mission is to enable direct, on‑demand, secure, and scalable energy distribution and data processing from space, supporting the expanding orbital economy, ISAM operations, remote regions, and military bases. Founded in 2024 by Baiju Bhatt (co‑founder of Robinhood), the company has raised approximately $365 million from investors including Index Ventures, Andreessen Horowitz, and Breakthrough Energy Ventures. The team includes alumni of SpaceX, Blue Origin, Stoke Space, Astranis, and NASA.

About the Role

As a Senior Manufacturing Engineer, you will establish how the rocket engine is made while building a factory from the ground up. You will make key decisions about hardware production, equipment purchases, and process development, and you will be accountable for delivering hardware—not merely supporting it. You will direct design‑for‑manufacturability (DFM) for new and existing components, set manufacturing direction, define build and inspection methods, specify tooling and equipment, and own the results when hardware reaches the build cell.

Responsibilities

• Define the manufacturing concept of operations (CONOPS) and the DFM strategy for your hardware, covering production methods, equipment selection, and build sequence.
• Foster a culture of creativity for every design and manufacturing challenge, ask hard questions, own each fix or improvement, and see it through to completion.
• Support facility layout and planning; identify, specify, and purchase capital equipment, then install, integrate, and qualify the equipment.
• Design tooling and fixtures to support all processes from machining, welding, assembly, to handling and transport.
• Lead the process qualification plan for your hardware in partnership with Materials & Processes and Quality teams.
• Manage supplier interactions for externally routed parts and processes, including process capability and first‑article inspections.
• Oversee qualification of new processes brought in‑house.
• Author all build documentation for your hardware, including routings, work instructions, process specifications, and the manufacturing bill of materials, using engineering judgment to determine the necessary level of detail.
• Own your hardware’s delivery, build cycle time, yield, and rate readiness; identify and resolve constraints, then scale the process from first article to repeatable production.
• Ensure configuration and pedigree are tracked throughout the entire build and test process; manage disposition of nonconforming hardware, lead rework and repair efforts, resolve root causes, and oversee nonconformance reports from creation to closure.
• Mentor team members within and outside the manufacturing engineering group.

Basic Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, Materials Science, or equivalent experience.
• Comprehensive understanding of mechanical design and manufacturing principles, including proficiency with GD&T per ASME Y14.5, tolerance stack analysis, and dimensional inspection techniques such as CMM, Faro Arm, Blue Light Scan, and manual inspection.
• Demonstrated hands‑on ownership of build and assembly processes on the manufacturing floor.
• Proficiency in CAD.
• Excellent written and verbal communication skills, with a proven ability to facilitate and resolve challenging technical discussions.
• Experience evaluating and dispositioning nonconforming hardware and developing detailed rework or repair plans.

Preferred Qualifications

• Minimum of 8 years of hands‑on experience in hardware manufacturing, utilizing methods such as machining, additive manufacturing, welding, brazing, forming, casting, forging, cleaning, non‑destructive testing, precision assembly, and acceptance testing of integrated hardware.
• Background spanning multiple product lines and manufacturing methods.
• Proven track record in establishing new factories or production lines, and/or transferring qualified manufacturing processes between sites.
• Extensive development‑phase involvement, including taking hardware from concept through first article and qualification to repeatable production at rate.
• Proficiency with Product Lifecycle Management (PLM) and Manufacturing Execution System (MES) software.
• Demonstrated capability in developing work instructions and process specifications, and qualifying them through continued conversations and iteration.
• Proven skillset in the design, analysis, and procurement of tooling for manufacturing and assembly applications throughout the product lifecycle.
• Proficiency in Siemens‑based CAM and/or machine languages.

Compensation and Benefits

• Salary range: $134,434 – $188,207 annually (base salary depends on skills, experience, qualifications, and internal equity).
• Equity in Cowboy Space Corp.
• Medical, dental, and vision insurance for employees and eligible dependents.
• 401(k) retirement savings plan.
• Paid time off.
• 10 paid holidays per calendar year.
• Paid parental leave.
• Relocation assistance, if applicable.
• Daily lunch in the office and a fully stocked kitchen with beverages and snacks.

ITAR Requirements

To conform to U.S. Government space‑technology export regulations, including the International Traffic in Arms Regulations (ITAR), applicants must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.