Senior Thermal Engineer – Constellations

About the Role

We are seeking a Senior Thermal Engineer to lead the thermal design and analysis for both satellite payloads and integrated in-space constellation solutions. This role is central to ensuring reliable performance of a diverse array of high-power payload systems operating in LEO and other orbital regimes. The ideal candidate brings deep expertise in thermal management of space-qualified hardware, RF / Opto-electrical components, radar systems, and/or specialized payload types, along with the ability to drive cross-disciplinary design integration across payload, mechanical, avionics, and power subsystems.

Responsibilities

• Lead thermal design & analysis for satellite-based, high-power payloads and associated power electronics.
• Develop detailed thermal models using tools such as Thermal Desktop, SINDA/FLUINT, or equivalent, covering conduction, radiation, and convection regimes as appropriate.
• Define and manage thermal interfaces across payload subsystems, including radiators, heat pipes, loop heat pipes, cold plates, and structural elements.
• Perform transient and steady-state thermal analyses to validate performance under mission profiles, including peak duty cycles, eclipse transitions, and worst-case environmental conditions.
• Develop thermal architecture for common bus/payload configurations reused across a production block, including tailoring for orbit plane, beta angle range, and payload variant.
• Select and defend the appropriate thermal qualification, margin, and acceptance approach based on build rate, mission class, and design life; tailor requirements per SMC-S-016 / MIL-STD-1540 as applicable.
• Define thermal model correlation strategy under limited test data, extending correlated models across the rest of a production block.
• Address LEO thermal cycling fatigue over high cycle counts (~5,000+ eclipse cycles/year) on joints, solder, TIMs, and coatings across design life.
• Drive design-for-manufacturability of thermal hardware at rate, leveraging parametric or automated thermal modeling workflows to support rapid trades.
• Evaluate COTS or commercial-grade thermal components where mission class permits, and manage heater power budget as a fleet-level EPS driver.
• Support design-for-demise and material selection for disposal casualty risk (ODMSP).
• Assess manufacturability, cost, and schedule impact of thermal hardware choices for production at scale.
• Support thermal design and analysis concurrently across multiple constellation and payload programs, prioritizing effort against shifting schedules and design maturity.
• Collaborate closely with payload subject matter experts, mechanical, power, and systems engineering teams to ensure thermal constraints are integrated into payload element layout and packaging.
• Establish thermal requirements, margins, and verification plans aligned with mission reliability and lifetime goals.
• Drive thermal design trades balancing performance, mass, power consumption, manufacturability, and cost for both space and ground systems.
• Contribute to major technical design reviews and serve as a key technical authority for the thermal system.
• Mentor junior engineers and contribute to organizational best practices in thermal engineering.

Qualifications

• Bachelor's degree in mechanical engineering, aerospace engineering, physics, or related field.
• 7+ years of experience in thermal engineering for aerospace systems and/or high-performance electronics.
• Demonstrated experience with spaceborne thermal design, including vacuum environments, radiation heat transfer, and flight hardware qualification.
• Experience with thermal modeling tools (e.g., Thermal Desktop, SINDA/FLUINT, ANSYS Icepak, or equivalent).
• Knowledge of materials, coatings, and thermal interface technologies suitable for space systems.
• Familiarity with environmental standards (e.g., NASA, ESA, MIL-STD) and qualification testing.
• Exceptional communication skills, with a demonstrated ability to influence and guide multidisciplinary teams.
• Ability and willingness to obtain and maintain a TS//SCI security clearance.
• Must be a U.S. citizen or national, U.S. permanent resident (current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Preferred Qualifications

• Master's or PhD degree in mechanical engineering, aerospace engineering, physics, or related field.
• Active TS//SCI clearance.
• Experience supporting capture and proposal efforts for new business opportunities.
• Background in space-based antenna systems or similar high-power payload systems.
• Experience with thermal management of high-power-density electronics such as T/R modules, phased array apertures, or laser communication terminals.
• Experience with advanced cooling techniques, including loop heat pipes, vapor chambers, and liquid cooling systems.
• Experience on a proliferated LEO or other high-rate satellite program.
• Experience with thermal cycling / ESS / HALT-HASS-style screening, including safety-of-screen or damage accumulation analysis.

Location: This role can be based at any of the following Blue Origin locations: Denver, CO; Los Angeles, CA; Space Coast, FL; Reston, VA; Huntsville, AL; or Kent, WA (Seattle area). Relocation assistance is available.

Travel: Up to 25% travel may be required depending on work location and program needs.

Benefits

• Medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability.
• 401(k) with a company match of up to 5%.
• Education Support Program.
• Stock Options for all regular employees (working at least 20 hours/week).
• Paid Time Off: Up to four (4) weeks per year based on weekly scheduled hours, and up to 14 company-paid holidays.

Pay

Base Pay Range:

• CA: $156,802.00 - $219,522.45
• CO: $144,179.00 - $201,849.90
• WA: $156,802.00 - $219,522.45
• VA: $156,802.00 - $219,522.45

Other site ranges may differ.