Materials & Processes Engineer — Satellite & Payloads - TeraWave

Application close date:

Applications will be accepted on an ongoing basis until the requisition is closed.

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.

TeraWave satellites and payloads must survive launch and long-duration LEO/MEO operation while being manufacturable at constellation scale. Success depends on disciplined control of structural and thermal materials, finishes, joining, printed wiring assemblies, RF and optical hardware, mechanisms, connectors, wire and cable, adhesives, coatings, thermal interfaces, contamination, corrosion, flammability, and supplier processes.

As the TeraWave M&P Engineer for Satellite and Payloads, you will establish and execute materials and process controls across spacecraft bus systems and RF and optical payloads. You will protect mechanical, electrical, thermal, RF, and optical performance, reliability, workmanship, and production yield from early design through fleet sustainment.

Special Mentions

• Relocation provided
• Travel: Up to 15% as program needs require

Responsibilities include but are not limited to:

• Develop, maintain, and execute the TeraWave Materials and Processes Plan and approved materials/processes lists across spacecraft bus systems and RF and optical payloads, coordinated with the program standards plan and product-assurance framework.
• Provide M&P technical authority for spacecraft structures and mechanisms, thermal hardware, RF and optical payload hardware, solar-array assemblies, propulsion hardware, avionics enclosures, CCAs, printed wiring boards, power electronics, batteries, magnetics, connectors, harnesses, cable shielding, bus bars, fasteners, conformal coatings, adhesives, potting, encapsulation, staking, thermal interface materials, lubricants, and surface finishes.
• Review drawings, material specifications, process specifications, source-control documents, supplier plans, and manufacturing instructions for compliance, completeness, producibility, and verification.
• Select and qualify materials and processes for vacuum, radiation, atomic oxygen, thermal cycling, humidity/storage, contamination, corrosion, charging, high voltage, and launch environments.
• Establish and manage prohibited/restricted materials controls, including pure tin/tin whiskers, cadmium, zinc, mercury, red plague, galvanic couples, halogens, silicone contamination, lead-free assembly, and material shelf-life concerns.
• Define requirements for soldering, crimping, splicing, bonding, welding, brazing, plating, cleaning, coating, torque, cure, bakeout, lubrication, handling, and repair/rework of spacecraft bus and payload assemblies.
• Partner with harness engineering on wire/cable selection, insulation compatibility, outgassing, shielding/termination materials, connector finishes, bend/flex life, routing environments, workmanship, and installation controls.
• Partner with EEE Parts and PCB/CCA teams on package/board compatibility, moisture sensitivity, solder-joint reliability, underfill/adhesive use, CTE mismatch, cleanliness, conductive-anodic-filament risk, and manufacturing process windows.
• Partner with Radiation Engineering to assess radiation degradation of polymers, adhesives, coatings, optical materials, insulation, and thermal-control materials.
• Plan and oversee coupon, material, process, and workmanship qualification; define acceptance criteria and verification methods; review test data and qualification reports.
• Support supplier assessment, special-process approval, process capability, first-article reviews, audits, nonconformances, MRB, failure analysis, and corrective action.
• Drive design-for-manufacture and design-for-automation improvements that preserve mission assurance while enabling high-rate, repeatable production.
• Maintain configuration control and traceability of approved materials, processes, deviations, shelf-life extensions, substitutions, and supplier changes.
• Investigate contamination, corrosion, delamination, cracking, insulation damage, solder/interconnect failures, plating defects, and other material/process anomalies.

Minimum Qualifications

• B.S. in materials science/engineering, metallurgy, chemical engineering, mechanical engineering, electrical engineering, chemistry, or a related technical field.
• 5+ years of experience in aerospace materials and processes, spacecraft or payload hardware, electronics manufacturing, mechanisms, optical/RF hardware, or another high-reliability product.
• Working knowledge across several relevant areas such as metals and composites, joining, surface treatments, lubrication, adhesives/coatings, contamination, corrosion, thermal-control materials, soldering, PCB/CCA fabrication, harness processes, connectors/plating, polymers, or special-process qualification.
• Experience reviewing engineering drawings/specifications, qualifying materials or processes, and dispositioning nonconformances.
• Ability to connect material/process choices to electrical, mechanical, thermal, radiation, reliability, and manufacturing outcomes.
• Ability to work directly with designers, technicians, manufacturing engineers, quality, supply chain, and external suppliers.
• 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

• M.S. or Ph.D. in materials science, metallurgy, chemistry, chemical engineering, or a related discipline.
• Experience with spacecraft vacuum, atomic oxygen, radiation, charging, contamination, and thermal-cycle environments.
• Familiarity with NASA-STD-6016, NASA workmanship standards, IPC J-STD-001 Space Addendum, IPC-A-610/620, ASTM E595, and relevant military/industry specifications.
• Experience with high-voltage insulation systems, corona/Paschen considerations, creepage/clearance, arc tracking, and power-electronics packaging.
• Experience qualifying automated or high-rate electronics/harness production processes and using statistical process control.
• Experience with failure analysis methods such as microscopy, cross-sectioning, SEM/EDS, X-ray/CT, FTIR, DSC/TGA, ion chromatography, or mechanical testing.
• Experience with batteries, solar arrays, RF hardware, photonics, or optical terminal material/process constraints.

Base Pay Range for:

CA applicants is $145,188.00 - $203,263.20
CO applicants is $133,500.00 - $186,898.95
WA applicants is $145,188.00 - $203,263.20

Other site ranges may differ

Culture Statement

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.

Export Control Regulations

Applicants for employment at Blue Origin must be a U.S. citizen or national, U.S. permanent resident (i.e. current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Background Check

• Required for all positions: Blue’s Standard Background Check
• Required for Certain Job Profiles: Defense Biometric Identification System (DBIDS) background check if at any time the role requires one to be on a military installation
• Required for Certain Job Profiles: Drivers who operate Commercial Motor Vehicles with a Gross Vehicle Weight (GVW), Gross Vehicle Weight Rating (GVWR) or combination of power unit and trailer that meets or exceeds 10,001 lbs. and/or transports placardable amounts of hazardous materials by ground in any vehicle on a public road while in commerce, may be subject to additional Federal Motor Carrier Safety Regulations including: Driver Qualification Files, Medical Certification (obtained before onboarding), Road Test, Hours of Service, Drug and Alcohol Testing, vehicle inspection requirements, CDL requirements (if applicable) and hazardous materials transportation/shipping training.
• Required for certain Job Profiles: Ability to obtain and maintain Merchant Mariner Credential, which includes pre-employment and random drug testing as well as DOT physical

Benefits

• Benefits include: 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%, and an 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. Bonus amounts and eligibility are not guaranteed and subject to change and cancellation. Please check with your recruiter for more details.

Equal Employment Opportunity

Blue Origin is proud to be an Equal Opportunity/Affirmative Action Employer and is committed to attracting, retaining, and developing a highly qualified and dedicated work force. Blue Origin hires and promotes people on the basis of their qualifications, performance, and abilities. We support the establishment and maintenance of a workplace that fosters trust, equality, and teamwork. We provide all qualified applicants for employment and employees with equal opportunities for hire, promotion, and other terms and conditions of employment, regardless of their race, color, religion, sex, sexual orientation, gender identity, national origin/ethnicity, age, physical or mental disability, genetic factors, military/veteran status, or any other status or characteristic protected by federal, state, and/or local law. Blue Origin will consider for employment qualified applicants with criminal histories in a manner consistent with applicable federal, state, and local laws, including the Washington Fair Chance Act, the California Fair Chance Act, the Los Angeles Fair Chance in Hiring Ordinance, and other applicable laws. For more information on “Know Your Rights,” please see here.

Affirmative Action and Disability Accommodation

Applicants wishing to receive information on Blue Origin’s Affirmative Action Plans, or applicants requiring a reasonable accommodation in order to participate in the application and/or interview process, please contact us at EEOCompliance@blueorigin.com. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.