Senior Reliability Engineer - Hardware Systems

Application close date: Applications will be accepted on an ongoing basis until the requisition is closed. 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 is pioneering the future of space-based communications with TeraWave, a revolutionary satellite communications network designed to deliver symmetrical data speeds of 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), providing enterprise-grade connectivity for critical operations worldwide. Role Overview We are seeking a Senior Reliability Engineer to own the reliability strategy, testing framework, and environmental validation for our next-generation satellite user terminal hardware. In this role, you will design and execute advanced testing protocols to ensure high-power, electronically steered systems perform reliably in extreme outdoor environments. You will collaborate closely with electrical, mechanical, and RF teams to identify design vulnerabilities, predict product lifetime, and drive hardware improvements prior to mass production. Core Responsibilities Design and execute reliability test plans, including Highly Accelerated Life Testing (HALT), Highly Accelerated Stress Screen (HASS), and Environmental Stress Screening (ESS). Set up and oversee physical testing programs for weather-proofing, including ingress protection (IP67+ water/dust), UV exposure degradation, solar radiation, salt fog corrosion, and extreme thermal cycling. Lead deep-dive root cause failure analysis on electrical components, PCB solder joints, materials, and structural interfaces using tools like X-ray, microscopy, and cross-sectioning. Ownership of DFMEA (Design Failure Mode and Effects Analysis). Develop physics-of-failure models to predict product lifetime, Mean Time Between Failures (MTBF), and warranty risks. Collaborate with mechanical engineers on FEA/CFD results and electrical engineers on Power Delivery Network (PDN) profiles to target specific high-stress areas (thermal hotspots, high vibrational loads) during physical testing. Work with external test labs to validate regulatory compliance standards and ensure component suppliers meet strict quality and reliability baselines. Required Qualifications Bachelor's degree in mechanical engineering, Electrical Engineering, Materials Science, or Reliability Engineering. 7+ years of experience in hardware reliability engineering, validation testing, or failure analysis for outdoor electronics, aerospace hardware, automotive systems, or telecom infrastructure. Direct experience operating environmental chambers, vibration/shaker tables, and electronic thermal cycle systems. Proficiency with reliability statistics and software tools (e.g., ReliaSoft, Minitab, JMP) to analyze life data using Weibull distributions and accelerated testing models. Proven track record of leading cross-functional DFMEA sessions and translating failure risks into concrete hardware design modifications. Preferred Qualifications Master's degree in mechanical engineering, Electrical Engineering, Materials Science, or Reliability Engineering. Understanding of long-term environmental degradation, micro-cracking, and moisture absorption in RF-transparent plastics (e.g., ASA, Polycarbonate, Composites). Knowledge of failure mechanisms in High-Density Interconnect (HDI) PCBs, such as thermal fatigue of solder joints, tin whiskers, or board warpage under dynamic thermal loads. Familiarity with telecom and aerospace environmental standards, such as MIL-STD-810, IEC 60068, GR-487, or automotive AEC‑Q100. Base Pay Range for: CA applicants is $197,529.00 - $276,539.55; WA applicants is $197,529.00 - $276,539.55. 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 (CDL drivers only), 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 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 workforce. 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 Affiantive Action Plans, or applicants requiring a reasonable accommodation in order to participate in the application and/or interview process, please contact us at View email address on click.appcast.io. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request. #J-18808-Ljbffr Blue Origin