Senior Manufacturing Opto-Mechanical & Sensor DFX Engineer

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!

This role is part of Blue Origin Operations, which is comprised of Integrated Supply Chain, Test Operations, Safety, Quality, and Mission Assurance. This includes Manufacturing and Supply Chain support across all Blue Origin facilities.

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 Opto-Mechanical & Sensor DFX Engineer, you will own the end-to-end opto-mechanical and sensor assembly design integration of TeraWave modules — bridging precision optical alignment, sensor integration, mechanical packaging, 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, aligned, and shipped complex opto-mechanical and sensor 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:

Opto-Mechanical & Sensor Assembly Design, Integration & Manufacturing

• Lead opto-mechanical assembly design for optical communication modules and sensor subsystems: optical mounts, alignment mechanisms, beam-path integration, sensor packaging, and mechanical integration of precision optical and sensing hardware.
• Own opto-mechanical and sensor assembly process development — including alignment procedures, active/passive alignment tooling, bonding, athermalization, and integration workflows — to ensure robust, repeatable assembly.
• Manage opto-mechanical and sensor BOM procurement, vendor coordination, tolerance and alignment budget analysis, and assembly oversight.
• Drive first-article inspection, optical performance validation, process validation, and manufacturing readiness reviews to support production ramp.

Design for Excellence (DFX)

• Drive Design for Excellence (DFX) principles — DFM, DFT, DFA, DFR, and DFS — across the full opto-mechanical and sensor assembly lifecycle to ensure hardware scales from prototype through volume production for TeraWave operations.
• Design for Manufacturability (DFM): Optimize optical mount geometry, material selection, alignment features, and assembly processes to maximize yield and minimize cost at constellation-scale production volumes.
• Design for Test (DFT): Integrate optical access points, alignment references, sensor test features, and fixturing to enable efficient optical performance verification, factory acceptance, and in-field diagnostics.
• Design for Assembly (DFA): Simplify part count, alignment features, fastening and bonding methods, and integration steps to reduce alignment time, rework, and error rates on the line.
• Design for Reliability (DFR): Apply tolerance stack-up and alignment budget analysis, worst-case analysis, FMEA, thermal-mechanical and vibration analysis, and reliability prediction to ensure stable optical performance and long-duration operation in the orbital environment.
• Design for Serviceability/Supply Chain (DFS): Coordinate with supply chain and manufacturing partners to drive component standardization, second-sourcing strategies, and obsolescence mitigation across the production lifecycle.
• Partner with manufacturing, quality, and supply chain teams to define acceptance criteria, drive yield optimization, and support production ramp for sustained TeraWave operations.

Minimum Qualifications:

• Bachelor's degree in Optical Engineering, Mechanical Engineering, Physics, or a related field.
• 10+ years of experience in opto-mechanical design, sensor integration, or precision mechanical assembly in a product development and volume production environment.
• Experience designing opto-mechanical assemblies with precision optical alignment, tight tolerances, and thermal-mechanical considerations; proficiency in SolidWorks, Creo, NX, or equivalent CAD tools.
• Hands-on experience with optical alignment processes, sensor integration, tooling and fixture development, bonding, and line bring-up.
• Demonstrated application of DFX principles (DFM/DFT/DFA/DFR) in bringing opto-mechanical or sensor assemblies from design into volume production.
• Excellent technical documentation and communication skills.

Preferred Qualifications:

• Master's degree in Optical, Mechanical, or Photonics Engineering.
• 15+ years of relevant experience.
• Experience with free-space optics, fiber optics, laser communications, or precision beam-steering systems.
• Experience with optical alignment budget analysis, athermalization techniques, and GD&T (ASME Y14.5).
• Experience designing and manufacturing opto-mechanical or sensor hardware for space, aviation, or other high-reliability thermal-vacuum environments.
• Experience with structural, thermal, or optical performance analysis (FEA, STOP analysis) in a design context.
• Background in production hardware including comprehensive DFX practices (DFM/DFT/DFA/DFR), alignment process optimization, supply chain coordination, and yield optimization at scale.
• Hands-on environmental qualification testing (TVAC, vibration, EMI/EMC).

Why Blue Origin

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

Base Pay Range for:

CA applicants is $156,802.00 - $219,522.45

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 View email address on aiapply.co. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.