Mechanical Engineer - Electronics Packaging - TeraWave

Blue Origin • El Segundo, CA

1d • $121,023 - $169,432

About The Position

This role is part of TeraWave, a satellite communications network designed to deliver symmetrical data speeds of up to 6 Tbps anywhere on Earth. This network will service tens of thousands of enterprise, data center, and government users who require reliable connectivity for critical operations. 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! About the Role: 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 optomechanical packaging for fiber/laser amplifier systems used in space optical communication links. You will own the mechanical design from concept through qualification and production, ensuring alignment stability, survivability through launch, and reliable on-orbit performance.

Requirements

• BS/MS in Mechanical Engineering or related field
• 5+ years in opto ‑ mechanical or high ‑ reliability electronics packaging, preferably aerospace or similar environments
• Proficiency with 3D CAD and drawings (e.g., Creo, NX, or SolidWorks); strong GD&T (ASME Y14.5) and tolerance analysis
• Demonstrated structural and thermal design skills; experience with FEA and thermal modeling supported by hand calculations
• Experience taking hardware from prototype through environmental qualification and into production
• Hands ‑ on assembly/alignment experience in lab or cleanroom settings; fixture and tooling design
• Clear communicator with strong cross ‑ functional collaboration and documentation skills

Nice To Haves

• Thermal analysis tools (e.g., Thermal Desktop/SINDA, ESATAN-TMS, Icepak /FLOTHERM) and test/model correlation
• Packaging of fiberoptic modules (spools, WDMs, isolators, combiners, pump diodes) and associated mechanical constraints
• Knowledge of space materials/coatings, contamination control, and outgassing (e.g., ASTM E595) and venting practices
• Experience with MLI, thermal straps/heat pipes, TECs/heaters, and thermal control interface to electronics
• Vibration and shock design/test (random vibe, SRS); fastener/joint analysis and fracture-control awareness
• Supplier development and manufacturing processes (CNC machining, sheet metal, additive, brazing); PLM/ECO and configuration management

Responsibilities

• Define requirements, interfaces, and budgets with photonics, electrical, systems, and manufacturing teams
• Develop packaging architectures for amplifier modules: chassis, mounts, fiber routing/strain relief, fixtures, enclosures, and contamination control
• Create CAD models and drawings; perform tolerance stack ‑ ups; author assembly procedures and work instructions
• Design for thermal performance: conduction/radiation paths, heat spreaders/straps, TEC/heater integration, emissivity coatings, and MLI; build and correlate thermal models
• Perform structural analyses (hand calculations and FEA) for static, modal, random vibration, and shock; fastener/joint analysis and margin reporting
• Manage fiber ‑ specific mechanics: bend radius, spooling, clamps, feedthroughs, and connector strain relief
• Select space ‑ appropriate materials and finishes considering outgassing, cleanliness, venting, and surface treatments
• Support environmental testing (TVAC, thermal cycling, vibration, shock): test setup, instrumentation, data review, and corrective actions
• Collaborate with suppliers/CMs on manufacturability, quality, and lead ‑ time; drive DFM/DFA and transition to production
• Own BOMs and configuration control throughout the product lifecycle

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%, and an Education Support Program.
• 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.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level