TCA Mechanical Design Engineer Level 1

Cowboy Space Corp. is building the infrastructure to power and connect the orbital economy. Our satellites operate in Low Earth Orbit to collect sunlight and enable a new class of capabilities—from powering on‑orbit compute, to transmitting energy via infrared lasers (space‑to‑earth and space‑to‑space), to delivering secure, high‑bandwidth optical data. Founded in 2024 by Baiju Bhatt (co‑founder of Robinhood), Cowboy Space Corp. is backed by leading investors and built by a team from top aerospace and defense organizations.

About the Role

We are seeking a TCA Mechanical Design Engineer Level 1 who is eager to build depth in manufacturing processes, tooling design, and specialized fabrication methodologies for rocket engine injector, combustion chamber, and nozzle development. The ideal candidate pairs a strong mechanical engineering foundation with hands‑on shop and lab experience from internships, co‑ops, or student design‑build‑test teams. This is a real ownership role from day one: you will own TCA hardware through rapid design/build/test cycles, with senior TCA engineers to learn from. You will work closely with propulsion, structures, thermal, materials and processes, manufacturing, and test operations. This position is located onsite in Kent, WA.

Responsibilities

• Own end‑to‑end TCA hardware lifecycle from requirements through manufacturing to flight qualification.
• Lead mechanical design optimized for manufacturability, applying physics‑based analysis — hand calculations, thermal and structural FEA, and tolerance stack‑ups.
• Implement advanced manufacturing techniques: additive manufacturing, precision CNC machining, EDM, and specialized joining (e.g., laser welding, vacuum brazing, diffusion bonding).
• Design tooling, fixtures, and work‑holding solutions for rapid development and repeatable production.
• Develop and qualify manufacturing process parameters for novel materials and geometries.
• Plan and execute hot‑fire test campaigns, analyze results, and lead rapid redesign efforts balancing performance with manufacturing constraints.
• Release production‑ready models, drawings, specifications, and release documentation.
• Work directly with machinists, welders, and technicians on the shop floor to close the loop between design intent and what actually gets built.

Basic Qualifications

• Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering.
• 1+ years of experience in mechanical design for rocket engine or comparable high‑performance hardware (internships, co‑ops, competition or research team experience count).
• Strong mechanical design proficiency with DFM/DFA emphasis, leading to hands‑on fabrication, assembly or component manufacturing experience.
• Proficiency with 3D CAD (NX, SolidWorks, CATIA, or Creo), structural analysis tools, and creating engineering drawings to ASME Y14.5 GD&T standards.
• Strong fundamentals in thermodynamics, fluid dynamics, and structural mechanics.
• Must be a U.S. citizen or national, lawful permanent resident, 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.

Preferred Qualifications

• 2+ years of experience with rocket engine TCA hardware, including component lifecycle ownership through production.
• Hands‑on experience with CNC machining, welding/brazing, or additive manufacturing.
• Design for Additive Manufacturing (DfAM) experience.
• Precision machining knowledge: 5‑axis CNC, high‑speed machining, Swiss machining.
• Specialized joining expertise: vacuum brazing, electron beam/laser welding, friction stir welding.
• Tooling design: fixtures, EDM electrodes, CMM/welding fixtures.
• Experience with Ansys Mechanical, Fluent, or Thermal Desktop.
• Master's degree in an engineering discipline.
• Leadership role on a student rocketry, Formula SAE, or similar design‑build‑test team.
• Willingness to spend regular time on the shop floor and at the test stand, including occasional off‑hours work during test campaigns.
• Experience at a fast‑moving, hardware‑focused startup or early‑stage program.

Compensation and Benefits

• Salary range: $100,000 – $150,000 annually.
• 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

Export Control Requirement: 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.