Sr. Mechanical Engineer - Avionics Mechanical Packaging - TeraWave Verified today
About TeraWave
Blue Origin is developing TeraWave, a satellite communications network delivering symmetrical data speeds of up to 6 Tbps. The constellation consists of optically interconnected satellites in low Earth orbit (LEO) and medium Earth orbit (MEO).
Role Overview
As Sr. Mechanical Engineer on the Spacecraft Bus Electrical Power Subsystem team, you will own mechanical packaging for the Power Management and Distribution (PMAD) Line Replaceable Unit (LRU). This includes enclosure design, card retention, thermal paths, connector access, mounting interfaces, serviceability, mass optimization, producibility, and integration flow. You will drive requirements, design, analysis, test, and critical review of avionics enclosures and assemblies housing electronic components, and mentor the mechanical team.
Key Responsibilities
- Provide leadership as a member of a cross-disciplinary team in a fast-paced design environment
- Participate in the entire design cycle of flight and mission-critical avionics
- Collaborate with customers and stakeholders to define requirements and design architecture
- Work with electrical engineering teams on PCB and interconnect systems, including thermal and structural analyses
- Lead design trade studies
- Design avionics enclosure solutions for performance and high reliability in harsh environments
- Create mechanical interface definitions, specifications, and control documents
- Create 3D CAD models, assemblies, part and assembly drawings, and installation drawings
- Build and evaluate prototype assemblies
- Create assembly aids and test fixtures
- Collaborate on and document mechanical best practices
- Plan and conduct engineering tests and data reviews
- Create and deliver presentations, proposals, and training material
- Review assembly instructions and support hardware builds
- Validate requirements through design, test, analysis, and inspection
- Support Production and Quality Engineering, including material defect dispositioning
- Manage product design configuration revisions through the product lifecycle
- Mentor and train junior engineers
- Review and approve designs and documentation created by team members
Minimum Qualifications
- B.S. degree in mechanical or aerospace engineering
- 7+ years recent experience designing ruggedized electronic enclosures or similar high-performance, high-reliability hardware
- Skilled with static structural, modal, random vibration, and thermal analysis
- Skilled with 3D CAD modeling programs (Creo preferred)
- Experience with FEA tools (Ansys preferred)
- Experience with Steinberg or Engelmeier solder fatigue analysis
- Skilled with GD&T implementation and analysis (ASME Y14.5)
- History of communicating design concepts and analysis results effectively
- History of demonstrating autonomous project leadership
- Technical authority recognized by the larger organization
- Experience with environmental testing including vibration, shock, thermal cycle
- Experience performing failure analysis and establishing root cause and corrective action
Preferred Qualifications
- Experience with avionics, power regulators and distributors, or batteries packaging
- Experience with aerospace, launch vehicle, or spacecraft avionics systems
- Experience with recent versions of Creo, Windchill, and Ansys Mechanical
- Experience with fatigue analysis and fracture mechanics
- Experience with aerospace industry standard structural analysis methods (Bruhn, Marks', Shigley, Steinberg, Roark's)
- Experience with environmental testing including EMI/RFI and TVAC
- Experience training and mentoring junior-level engineers
- Experience directing the activities of other engineers
- Hands-on, practical mechanical abilities
- Ability to be self-directed and balance multiple projects
- Flexibility and openness to varied assignments and learning new skills
- Ability to earn trust and maintain positive, professional relationships
Compensation
Base pay range varies by location: CA and WA applicants $145,188.00 to $203,263.20; CO applicants $133,500.00 to $186,898.95. Other site ranges may differ.
Employment Requirements
Applicants must be a U.S. citizen or national, U.S. permanent resident (Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum. Blue's Standard Background Check is required for all positions.