Spacecraft Harness Design Engineer III - TeraWave Verified today

About TeraWave

Blue Origin is developing TeraWave, a satellite communications network delivering symmetrical data speeds 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).

The Role

You will design harness systems for a mega-constellation of 5,408 satellites, where manufacturability, cost optimization, and production rate are first-order design drivers from day one. You will work across every subsystem on the vehicle: EPS power distribution, flight computer C&DH, GNC sensors, propulsion, solar array, RF and optical payloads, and thermal management, giving you broad spacecraft-level visibility.

Harness Design & Documentation

• Design, develop, and release spacecraft wire harness assemblies for bus, payload, and integration applications across the TeraWave satellite constellation
• Develop Bundle Interconnect Diagrams (BIDs) and Wire Interconnect Diagrams (WIDs) in coordination with LRU/box owners across all subsystems
• Produce harness engineering drawings including harness assembly drawings, installation drawings, and connector pin assignment drawings
• Create and maintain 3D harness routing models in Creo/Windchill, performing interference checks, bend radius verification, and mass/length estimation
• Work to harness specifications, workmanship standards, and design requirements aligned with Blue Origin command media

Connector & Interconnect Design

• Select connectors, backshells, contacts, and interconnect hardware appropriate for the space environment (vacuum, thermal cycling, radiation, vibration)
• Define connector keying, clocking, and pin assignments to ensure proper mating and prevent misconnection during integration
• Specify shielding termination methods (360° backshell termination, pigtail, drain wire) based on EMI/EMC requirements and signal type

Analysis & Verification

• Perform harness-related analyses including voltage drop, wire derating, current capacity, weight estimation, and thermal dissipation
• Support EMI/EMC analysis for harness segregation planning, separating power, signal, and RF runs per the Electromagnetic Effects Control Plan

Manufacturing & Integration Support

• Coordinate with manufacturing engineering on harness fabrication, support make/buy decisions, develop build instructions, and resolve production issues
• Support harness fabrication to specified workmanship standards
• Develop test procedures for harness acceptance testing (continuity, hipot, insulation resistance, megohm)
• Support vehicle integration and test, troubleshoot harness anomalies, process redlines, and support connector mate/demate operations
• Design harnesses for manufacturability and rate production, minimizing harness variants, standardizing connector families, and optimizing for assembly time at constellation scale

Minimum Qualifications

• Bachelor's degree in Electrical Engineering, Aerospace Engineering, Mechanical Engineering, or related technical field
• 5+ years of experience in spacecraft or satellite harness design, cable routing, or electrical integration
• Demonstrated experience producing harness assembly drawings, installation drawings, and connector pin assignment documentation
• Hands-on experience with BID/WID development and interface coordination across multiple subsystems
• Proficiency with electrical harness CAD tools (Creo Cabling / Routed Systems, Zuken, Capital Harness, Mentor/Siemens, or equivalent)
• Working knowledge of harness fabrication standards
• Understanding of EMI/EMC principles as applied to harness segregation, shielding, and grounding
• Familiarity with connector systems used in space applications (Micro-D, Nano-D, D-sub, circular MIL-DTL-38999, MIL-DTL-83513)
• Ability to read and interpret electrical schematics, block diagrams, and interface control documents
• 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

• 5+ years of experience in spacecraft harness design with at least one program through full lifecycle
• Experience with Creo Cabling / Routed Systems and Windchill PLM for harness configuration management
• Direct experience designing harnesses for satellite constellations or high-rate spacecraft or automotive production environments
• Experience with high-voltage (>50V) spacecraft power harness design
• Experience with harness weight optimization techniques for mass-constrained spacecraft
• Strong attention to detail and ability to manage multiple concurrent harness designs in a fast-paced environment
• Background in harness-level or system-level signal integrity analysis for high-speed data interfaces (Ethernet, SpaceWire, LVDS)
• Experience supporting harness fabrication shops, reviewing first articles, dispositioning nonconformances, and developing rework procedures

Compensation

Base Pay Range:

• CA applicants: $130,706.00 - $182,987.70
• CO applicants: $119,814.00 - $167,738.55
• WA applicants: $130,706.00 - $182,987.70

Other site ranges may differ.

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 (working at least 20 hours/week)
• Paid Time Off: up to four weeks per year and up to 14 company-paid holidays
• Bonuses may be eligible based on role type and job level