Mechanical Design Engineer III – Electric Propulsion Verified today
Role Overview
As an early member of the propulsion team at Blue National Security, you will lead development of Hall thruster-based electric propulsion subsystem mechanical designs. You will create fluid system designs informed by product requirements, development test results, and design for manufacturability and assembly reviews. Your experience in propellant feed system design will drive specifications from conceptual architecture through production optimization.
Key Responsibilities
- Author propulsion system designs and drawings, iteratively improving from concept to production
- Lead design reviews and coordinate inputs from thermal, propulsion, structures, test, and manufacturing engineering teams
- Work through iterative design, build, and test loops to ensure designs meet product requirements and Design for X (manufacturing, assembly, test, automation) considerations
- Formulate and lead trade studies to improve production efficiency and reduce defects
- Work with manufacturing and test engineers to design build and test tooling and fixtures
- Identify, communicate, and mitigate cost, schedule, and technical risks
- Coordinate with satellite vehicle integration teams on propulsion system interfaces and integration tooling
- Contribute to team growth through hiring assistance, identifying skill gaps, and mentoring junior members
Minimum Qualifications
- Bachelor of Science in Aerospace Engineering, Mechanical Engineering, or related technical field
- 5 or more years of career experience in propulsion system development, production, and test
- Experience supporting design and development of propulsion fluid and propellant feed system flight hardware in a production facility or laboratory
- Strong mechanical design and integration skills using 3-D CAD software (Creo Pro/E preferred)
- Proficiency with GD&T (ASME Y14.5) and dimensional variation analysis
- Experience designing hardware to meet thermal, vibration, shock, and vacuum testing requirements per MIL-STD-810, SMC-S-016, and MIL-STD-1540
- Experience with production lifecycle management (PLM) tools (Windchill preferred)
- Proven track record developing product designs
- Ability to earn trust, maintain positive professional relationships, and contribute to inclusive culture
- Ability to perform design analyses and present technical information in clear visual format
- Excellent verbal, written, and graphical communication skills
- Ability to work collaboratively in cross-functional, fast-paced environment
- Enthusiasm for mentoring, training, and supporting team members' technical development
Preferred Qualifications
- Experience designing complex integrated assemblies including high and low-pressure fluid systems, high voltage assemblies, high temperature assemblies, and electronics enclosures
- Electric propulsion production system-level design experience with Hall thrusters, hollow cathodes, feed systems, propellant tanks, harnessing
- Experience designing and operating fluid test equipment for product performance validation and verification
- Working knowledge of electric propulsion system operating principles and design practices
- Experience developing propulsion systems from concept to production through iterative design, build, and test
- Experience designing production hardware and optimizing for increasing production rates
- Quick learning ability with various software tools
- Experience with automated tooling and robotics design for automation
- Experience with AS9100 Quality Management System
- Expertise with analysis codes for flow applications: Nastran, ANSYS, Optistruct, LS/Dyna, Abaqus
- Experience coordinating vehicle integration on line replaceable unit (LRU) interface design
- Experience with Optimization and Design of Experiments (DOE) methods
Physical Requirements
- Ability to support production floor activities
Compensation and Work Arrangement
Base pay range for Washington applicants: $121,023.00 to $169,432.20. Other site ranges may differ.
Relocation provided. Travel expected up to 25% of the time.
Employment Details
Applicants must be a U.S. citizen or national, U.S. permanent resident (Green Card holder), or lawfully admitted as a refugee or with asylum status.
Standard background check required for all positions.
Benefits include medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability, 401(k) with company match up to 5%, and Education Support Program. Stock options available for regular employees working at least 20 hours per week. Paid time off up to four weeks per year based on scheduled hours, plus up to 14 company-paid holidays. Bonus eligibility dependent on role type and job level.