Sr Controls Engineer Verified today

Blue Origin Engines develops reusable, safe, and low-cost space vehicles and propulsion systems. The Controls team is responsible for the complete digital and physical control architecture for next-generation hardware, encompassing supervisory software, real-time PLC automation, instrumentation, and electrical distribution.

As a Senior Controls Engineer, you will design, develop, and validate control systems and algorithms that govern critical test infrastructure. You will translate requirements into robust, production-ready control architectures. This is a hands-on role requiring deep technical expertise in real-time systems, controls algorithms, and design validation.

Key Responsibilities

• Design and architect control systems: Develop supervisory software, real-time PLC logic, and embedded control algorithms for test facilities, test stands, and next-generation hardware. Define control strategies, sensor requirements, and feedback loops.
• Test facility operations support: Provide technical support during facility commissioning, test execution, and troubleshooting. Optimize control algorithms based on test data and operational feedback. Support transition of prototype controls into production-ready configurations.
• Real-time PLC and automation programming: Design, code, and integrate PLC logic across Siemens and Rockwell platforms. Develop deterministic, fail-safe control sequences for complex multi-system operations.
• Electrical architecture and instrumentation: Specify, design, and validate instrumentation strategies (sensors, transmitters, signal conditioning). Design electrical distribution, panel layouts, and integration of sensors and actuators into real-time control loops. Ensure compliance with electrical standards.
• Systems integration and validation: Collaborate with mechanical, thermal, fluids, and test operations teams to integrate controls into complete system architectures. Participate in design reviews, testing, and troubleshooting to ensure controls meet functional, safety, and performance requirements.
• Controls software development and lifecycle: Conduct code reviews, implement unit testing, and maintain configuration management rigor across development, test, and operational phases.
• Safety and standards compliance: Ensure designs comply with applicable controls standards. Support safety case development and certification activities.
• Documentation and knowledge transfer: Create comprehensive design documentation, functional specifications, software design documents, and operational procedures. Mentor junior engineers and support team knowledge transfer.

Minimum Qualifications

• B.S. degree in Electrical Engineering, Controls Engineering, Mechanical Engineering, Aerospace Engineering, or related discipline.
• 10 or more years of hands-on experience designing and implementing real-time control systems for complex hardware (propulsion systems, test facilities, industrial automation, or similar mission-critical environments).
• Deep proficiency in PLC programming (ladder logic, structured text) across at least two major platforms (Siemens TIA Portal, Rockwell Studio 5000). Demonstrated ability to code production-ready, safety-critical logic from requirements.
• Hands-on commissioning experience for complex test facilities; ability to troubleshoot and optimize controls during facility activation and operational ramp-up.
• Strong understanding of real-time systems architecture, including deterministic execution, interrupt handling, communication protocols (CAN, Ethernet/IP, Modbus, OPC), and fail-safe design patterns.
• Solid grasp of instrumentation and electrical systems: Sensor selection, signal conditioning, electrical distribution, grounding, EMI/RFI mitigation, and power system design.
• Experience integrating controls into multi-disciplinary systems (mechanical, thermal, electrical) with demonstrated ability to resolve cross-functional technical trade-offs.
• Familiarity with systems engineering concepts: Functional architecture, requirements traceability, interface control, and configuration management.
• Excellent technical communication skills: Ability to document designs, present to cross-functional teams, and interface with test operations and program leadership.
• 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

• M.S. degree in Controls Engineering, Electrical Engineering, or related discipline; PMP or INCOSE certification.
• Experience with advanced controls concepts: Model Predictive Control (MPC), adaptive controls, state estimation, or Kalman filtering applied to real hardware systems.
• Experience with hardware-in-the-loop (HIL) testbeds.
• Expertise in controls modeling and simulation: Hands-on experience with Matlab/Simulink, Labview, or equivalent; ability to develop and execute MIL/SIL/HIL test strategies for control algorithm validation.
• Experience with ECAD tools (AutoCAD Electrical, ePlan) for electrical architecture design and documentation.
• Proficiency with industrial SCADA/supervisory software (WinCC, Ignition, FactoryTalk).
• Experience with Git version control, CI/CD pipelines, and modern software development practices in embedded systems environments.
• Prior mentoring or technical leadership experience guiding junior engineers in controls design and implementation.

Compensation and Benefits

Base pay range for WA applicants: $197,529 to $276,539.55. 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%, and Education Support Program. Stock options for all regular employees (20 hours/week or more). Paid time off up to four weeks per year and up to 14 company-paid holidays.

Relocation assistance and regular schedules (5/2 or rotation 8/6, 16/12) available. Van Horn, TX site offers additional financial incentives including living allowance for employees permanently relocating or traveling to Van Horn 50% or more of the time.

Background Check and Export Control

Blue's Standard Background Check required for all positions. Additional background checks may be required based on military installation access or other job-specific requirements. Applicants must be a U.S. citizen or national, U.S. permanent resident, or lawfully admitted as a refugee or granted asylum.