Sr. Manufacturing Mechanical Assembly DFX Engineer

Application close date:

At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!  

Blue Origin's Emerging Systems business unit is building TeraWave, a satellite communications constellation powered by the most advanced optical communications architecture ever attempted: thousands of optically interconnected satellites delivering symmetrical data speeds of up to 6 Tbps anywhere on Earth, providing enterprise and hyperscale customers with resilient, scalable connectivity for critical operations where terrestrial infrastructure cannot reach.

As a Senior Manufacturing Mechanical Assembly DFX Engineer, you will own the end-to-end mechanical assembly design integration of TeraWave modules — bridging structural design, mechanical integration, and volume production readiness. As a foundational element of TeraWave operations, hardware must be architected not only for performance but for manufacturability, testability, reliability, and serviceability at constellation scale. This is a hands-on role for an engineer who has designed, integrated, and shipped complex mechanical assemblies in fast-moving, high-volume manufacturing environments and wants to apply that experience to hardware operating at orbital scale.

Special Mentions:

• Relocation assistance is available for qualified candidates.
• Travel: Up to 50%.

Responsibilities

• Lead and facilitate DFX reviews (DFM, DFA, DFT, DFC) throughout all phases of the product lifecycle, from concept through production
• Partner with design engineering teams to provide manufacturing feedback early in the design cycle, identifying risks and opportunities to improve producibility
• Analyze complex mechanical drawings, models (CAD), and assemblies to identify design features that may be difficult, costly, or risky to manufacture
• Develop and maintain DFX guidelines, best practices, and standards for machined parts, sheet metal, composites, castings, forgings, welded structures, and other manufacturing processes
• Drive design trade studies and cost-benefit analyses to support design optimization decisions
• Collaborate with suppliers and internal manufacturing teams to understand process capabilities and constraints
• Support cost reduction and producibility improvement initiatives on existing hardware
• Engage with quality engineering to identify and resolve design-driven quality issues
• Contribute to the development and review of GD&T (Geometric Dimensioning and Tolerancing) and tolerance stack-up analyses
• Support NPI (New Product Introduction) and production readiness reviews
• Provide technical input to make vs. buy decisions and manufacturing process selection
• Mentor junior engineers on DFX principles and manufacturing best practices

Minimum Qualifications

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or related technical discipline
• 10+ years of experience in mechanical design, manufacturing engineering, or a closely related field
• Strong working knowledge of DFM/DFA/DFX methodologies
• Proficiency in 3D CAD tools (NX, CATIA, SolidWorks, or equivalent)
• Experience reading and interpreting engineering drawings and GD&T per ASME Y14.5
• Familiarity with a broad range of manufacturing processes, including:
  • CNC machining
  • Sheet metal fabrication
  • Welding and joining
  • Composite manufacturing
  • Casting and forging
  • Additive manufacturing
• Excellent communication skills with the ability to clearly convey technical concepts to cross-functional teams
• Must be a U.S. citizen or permanent resident (required for access to export-controlled data)

Preferred Qualifications

• Master's degree in Mechanical or Manufacturing Engineering
• Experience in aerospace, defense, or space launch vehicle manufacturing environments
• Familiarity with AS9100 quality management systems
• Experience with tolerance stack-up analysis tools (e.g., 3DCS, VSA)
• Knowledge of lean manufacturing and continuous improvement methodologies (Six Sigma, Kaizen)
• Experience with Model-Based Definition (MBD) and paperless manufacturing environments
• Hands-on experience in a production or shop floor environment
• Background in cost modeling or should-cost analysis

At Blue Origin, we are driven by Gradatim Ferociter — "Step by Step, Ferociously." As a Senior Manufacturing Mechanical Assembly DFX Engineer, you will design and industrialize the foundational hardware connecting an orbital constellation at unprecedented scale, alongside world-class engineers solving problems at the intersection of advanced manufacturing, mechanical design, and spaceflight.

Base Pay Range for:

Other site ranges may differ

Culture Statement

Don’t meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.

Export Control Regulations

Applicants for employment at Blue Origin must be a U.S. citizen or national, U.S. permanent resident (i.e. current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Background Check

• Required for all positions: Blue’s Standard Background Check
• Required for Certain Job Profiles:  Defense Biometric Identification System (DBIDS) background check if at any time the role requires one to be on a military installation
• Required for Certain Job Profiles: Drivers who operate Commercial Motor Vehicles with a Gross Vehicle Weight (GVW), Gross Vehicle Weight Rating (GVWR) or combination of power unit and trailer that meets or exceeds 10,001 lbs. and/or transports placardable amounts of hazardous materials by ground in any vehicle on a public road while in commerce, may be subject to additional Federal Motor Carrier Safety Regulations including: Driver Qualification Files, Medical Certification (obtained before onboarding), Road Test, Hours of Service, Drug and Alcohol Testing, vehicle inspection requirements, CDL requirements (if applicable) and hazardous materials transportation/shipping training.
• Required for certain Job Profiles: Ability to obtain and maintain Merchant Mariner Credential, which includes pre-employment and random drug testing as well as DOT physical

Benefits

• Benefits include:  Medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability, 401(k) with a company match of up to 5%, and an Education Support Program.
• Stock Options for all regular employees (working at least 20 hours/week)
• Paid Time Off:  Up to four (4) weeks per year based on weekly scheduled hours, and up to 14 company-paid holidays.
• Dependent on role type and job level, employees may be eligible for benefits and bonuses based on the company's intent to reward individual contributions and enable them to share in the company's results, or other factors at the company's sole discretion. Bonus amounts and eligibility are not guaranteed and subject to change and cancellation. Please check with your recruiter for more details.

Equal Employment Opportunity

Blue Origin is proud to be an Equal Opportunity/Affirmative Action Employer and is committed to attracting, retaining, and developing a highly qualified and dedicated work force. Blue Origin hires and promotes people on the basis of their qualifications, performance, and abilities. We support the establishment and maintenance of a workplace that fosters trust, equality, and teamwork. We provide all qualified applicants for employment and employees with equal opportunities for hire, promotion, and other terms and conditions of employment, regardless of their race, color, religion, sex, sexual orientation, gender identity, national origin/ethnicity, age, physical or mental disability, genetic factors, military/veteran status, or any other status or characteristic protected by federal, state, and/or local law. Blue Origin will consider for employment qualified applicants with criminal histories in a manner consistent with applicable federal, state, and local laws, including the Washington Fair Chance Act, the California Fair Chance Act, the Los Angeles Fair Chance in Hiring Ordinance, and other applicable laws. For more information on “Know Your Rights,” please see here.

Affirmative Action and Disability Accommodation

Applicants wishing to receive information on Blue Origin’s Affirmative Action Plans, or applicants requiring a reasonable accommodation in order to participate in the application and/or interview process, please contact us at [email protected]. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.