Sr. Avionics Harnessing and Packaging Engineer Verified today

About the Role

As a Level 4 Harnessing and Packaging Engineer in Blue Origin's In-Space Systems business unit, you will serve as technical leader for all internal harnessing and packaging within the TeraWave flight product. You will mature designs for the space environment while optimizing them for efficient, large-scale automated manufacturing.

Key Responsibilities

• Design for Manufacturing and Assembly: Embed DFM/DFA principles into all internal harnesses, enclosures, PCB/PCBAs, and electronic assemblies throughout the design cycle.
• Production Transition Leadership: Own and lead the technical effort to transition product-internal harnessing and packaging designs from low-rate initial builds to high-rate production.
• Process Development: Collaborate with manufacturing engineers and suppliers to define, develop, and validate production processes, tooling, and test procedures.
• Technical Design: Design and release detailed 3D models and 2D drawings for all internal wire harnesses, cable assemblies, and electronics enclosures using Altium, Creo, SolidWorks, and Windchill. Perform trade studies on component selection, materials, and manufacturing techniques.
• Supplier Collaboration: Act as primary technical point of contact for external suppliers, guiding design intent and qualifying processes for high-volume production.
• Analysis and Verification: Oversee structural, thermal, and vibration analysis of electronic packaging. Develop and execute verification and validation test campaigns.
• Mentorship: Mentor junior engineers in design for manufacturing and product maturation best practices.

Required Qualifications

• B.S. degree in Mechanical, Electrical, Aerospace Engineering, or related technical field.
• 8+ years of experience in design and delivery of electronics packaging and/or harnessing for complex systems as an integrated part of a final product.
• Demonstrated hands-on experience leading transition of a product from prototype/development into high-rate production.
• Proven expertise in Design for Manufacturing (DFM), Design for Assembly (DFA), and cost reduction methodologies.
• Strong proficiency with 3D CAD software (Creo/SolidWorks preferred) for harnessing and mechanical design.
• Deep understanding of harness manufacturing processes, standards (e.g., IPC/WHMA-A-620), and quality control.
• Experience working through full engineering lifecycle: requirements definition, design, analysis, manufacturing, and testing.
• Must be U.S. citizen or national, U.S. permanent resident (current Green Card holder), or lawfully admitted as refugee or granted asylum.

Desired Qualifications

• M.S. degree in relevant engineering discipline.
• 10+ years of experience in aerospace, satellite, or high-volume electronics/automotive industries.
• Expert-level user of Creo Cabling/Harnessing module and Windchill PLM.
• Experience with ECAD/MCAD integration and tools (e.g., Zuken E3, Mentor Graphics).
• Experience with supply chain development and supplier qualification for high-reliability components.
• Hands-on experience with harness fabrication, rapid prototyping, and developing manufacturing work instructions.
• Knowledge of FEA tools (Ansys preferred) for structural and thermal analysis of electronics.

Compensation and Benefits

Base pay range for Colorado applicants: $144,179.00 to $201,849.90. Other site ranges may differ.

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%, education support program, stock options for regular employees, up to 4 weeks paid time off per year, and up to 14 company-paid holidays.

Additional Requirements

Background check required for all positions. Applications accepted on ongoing basis until requisition closes.