Sr. Mechanical Engineer – Avionics Packaging - TeraWave

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!

Blue Origin is pioneering the future of space-based communications with TeraWave, a revolutionary satellite communications network designed to deliver symmetrical data speeds of up to 6 Tbps anywhere on Earth. This multi-orbit constellation will consist of optically interconnected satellites in low Earth orbit (LEO) and medium Earth orbit (MEO), providing enterprise-grade connectivity for critical operations worldwide.

About the role

As part of the TeraWave Spacecraft Bus, you will be responsible for driving requirements, design, analysis, test, and critical review of avionics enclosures and assemblies which house electronic components. You will play a key role in developing the TeraWave Satellite system from concept through formal qualification and verification including integration and flight support activities. You will own mechanical packaging for the various Line Replaceable Unit (LRU), including enclosure, card retention, thermal paths, connector access, mounting interfaces, serviceability, mass optimization, producibility, and integration flow. Your work will support evolving LRU architectures.

The role is part of the In-Space Systems business unit, which is focused on addressing two of the most compelling challenges in spaceflight today: space infrastructure and increasing mobility on-orbit. We are seeking a Mechanical Engineer to architect, design, and validate the mechanical packaging for spacecraft LRUs. You will own the mechanical design from concept through qualification and production, ensuring alignment stability, survivability through launch, and reliable on-orbit performance.

Responsibilities

• Participate in the entire design cycle of flight and mission critical avionics Line Replacement Units (LRUs)
• Design and develop packaging architectures using DFM / DFA for avionics LRU enclosures
• Design avionics enclosure solutions for performance and high reliability in harsh environments
• Create mechanical interface definitions, specifications, and control documents
• Create 3D CAD models and assemblies, part and assembly drawings, installation drawings, and other required technical documentation
• Collaborate with the electrical engineering team to incorporate printed circuit board and interconnect systems, including thermal and structural analyses of these components
• Own BOMs and configuration control throughout the product lifecycle
• Build and evaluate prototype assemblies
• Create assembly aids and test fixtures
• Plan and conduct engineering tests and data reviews
• Review assembly instructions and support hardware builds
• Support environmental testing (TVAC, thermal cycling, vibration, shock): test setup, instrumentation, data review, and corrective actions
• Support Production and Quality Engineering as needed, including dispositioning material defects
• Manage revisions of the product design configurations through the product lifecycle

Requirements

• B.S. degree in mechanical or aerospace engineering
• 7+ years of recent experience designing ruggedized electronic enclosures or similar high-performance / high reliability hardware
• Familiarity with static structural, modal, random vibration, and thermal analysis
• Proficiency with 3D CAD and drawings (e.g., Creo, NX, or SolidWorks); strong GD&T (ASME Y14.5) and tolerance analysis
• Experience with environmental testing including vibration, shock, thermal cycle
• Experience performing failure analysis and establishing root cause / corrective action
• 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

• Experience with one or more of the following packaging disciplines: avionics, power regulators and distributors, batteries
• Experience with aerospace, launch vehicle, or spacecraft avionics systems
• Experience with FEA tools (Ansys preferred)
• Experience with recent versions of Creo, Windchill, Ansys Mechanical
• Experience with fatigue analysis and fracture mechanics
• Experience with additional environmental testing including EMI/RFI, TVAC
• Ability to be self-directed and balance several projects at one time

Pay

Base Pay Range for CO applicants is $133,500.00 - $186,898.95. WA applicants is $145,188.00 - $203,263.20. Other site ranges may differ.

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
• Dependent on role type and job level, employees may be eligible for benefits and bonuses based on the company's intent to reward individual contributions and enable them to share in the company's results, or other factors at the company's sole discretion