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Senior Thermal Engineer – Constellations Verified today

Blue Origin · 6 Locations · Mechanical · first seen 2026-09-23
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About the Role

Blue Origin is seeking a Senior Thermal Engineer to lead thermal design and analysis for satellite payloads and integrated in-space constellation solutions. This role ensures reliable performance of high-power payload systems operating in LEO and other orbital regimes. You will drive cross-disciplinary design integration across payload, mechanical, avionics, and power subsystems.

This position is part of the Blue National Security business unit's Advanced Systems organization, working on next-generation space systems for defense and civil missions.

Key Responsibilities

  • Lead thermal design and analysis for satellite-based, high-power payloads and associated power electronics
  • Develop detailed thermal models using Thermal Desktop, SINDA/FLUINT, or equivalent, covering conduction, radiation, and convection
  • Define and manage thermal interfaces across payload subsystems, including radiators, heat pipes, loop heat pipes, cold plates, and structural elements
  • Perform transient and steady-state thermal analyses to validate performance under mission profiles, including peak duty cycles, eclipse transitions, and worst-case environmental conditions
  • Develop thermal architecture for common bus/payload configurations reused across production blocks, tailored for orbit plane, beta angle range, and payload variant
  • Select and defend thermal qualification, margin, and acceptance approaches (protoflight, TVAC, thermal cycling screening) based on build rate, mission class, and design life per SMC-S-016 / MIL-STD-1540
  • Define thermal model correlation strategy under limited test data, extending correlated models across production blocks
  • Address LEO thermal cycling fatigue over high cycle counts (5,000+ eclipse cycles/year) on joints, solder, TIMs, and coatings
  • Drive design-for-manufacturability of thermal hardware at rate, leveraging parametric or automated thermal modeling workflows
  • Evaluate COTS or commercial-grade thermal components where mission class permits, managing heater power budget as a fleet-level EPS driver
  • Support design-for-demise and material selection for disposal casualty risk (ODMSP)
  • Assess manufacturability, cost, and schedule impact of thermal hardware choices for production at scale
  • Support thermal design and analysis across multiple constellation and payload programs, prioritizing effort against shifting schedules
  • Collaborate with payload experts, mechanical, power, and systems engineering teams to ensure thermal constraints integrate into payload element layout
  • Establish thermal requirements, margins, and verification plans aligned with mission reliability and lifetime goals
  • Drive thermal design trades balancing performance, mass, power consumption, manufacturability, and cost
  • Contribute to major technical design reviews as a key thermal system authority
  • Mentor junior engineers and contribute to organizational best practices

Minimum Qualifications

  • Bachelor's degree in mechanical engineering, aerospace engineering, physics, or related field
  • 7+ years of experience in thermal engineering for aerospace systems and/or high-performance electronics
  • Demonstrated experience with spaceborne thermal design, including vacuum environments, radiation heat transfer, and flight hardware qualification
  • Experience with thermal modeling tools (Thermal Desktop, SINDA/FLUINT, ANSYS Icepak, or equivalent)
  • Knowledge of materials, coatings, and thermal interface technologies suitable for space systems
  • Familiarity with environmental standards (NASA, ESA, MIL-STD) and qualification testing
  • Exceptional communication skills and demonstrated ability to influence and guide multidisciplinary teams
  • Ability and willingness to obtain and maintain a TS//SCI security clearance
  • 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

  • Master's or PhD degree in mechanical engineering, aerospace engineering, physics, or related field
  • Active TS//SCI clearance
  • Experience supporting capture and proposal efforts for new business opportunities
  • Background in space-based antenna systems or high-power payload systems
  • Experience with thermal management of high-power-density electronics such as T/R modules, phased array apertures, or laser communication terminals
  • Experience with advanced cooling techniques, including loop heat pipes, vapor chambers, and liquid cooling systems
  • Experience on a proliferated LEO or high-rate satellite program
  • Experience with thermal cycling / ESS / HALT-HASS-style screening, including safety-of-screen or damage accumulation analysis

Compensation and Location

Base pay ranges by location:

  • CA, WA, VA applicants: $156,802 - $219,522
  • CO applicants: $144,179 - $201,850
  • Other site ranges may differ

This role can be based at any of the following Blue Origin locations: Denver, CO; Los Angeles, CA; Space Coast, FL; Reston, VA; Huntsville, AL; or Kent, WA (Seattle area). Relocation assistance is available for candidates relocating to primary Blue Origin office locations. Up to 25% travel may be required depending on work location and program needs.

Benefits

  • Medical, dental, vision, basic and supplemental life insurance
  • Paid parental leave
  • Short and long-term disability
  • 401(k) with company match up to 5%
  • Education Support Program
  • Stock options for all regular employees (20+ hours/week)
  • Paid time off: up to 4 weeks per year and up to 14 company-paid holidays
  • Potential performance bonuses based on company discretion