Sr. Mechanical RF/Antenna Engineer - TeraWave

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! We are seeking a Senior Mechanical Engineer to support the design, development, flight validation, assembly, integration, testing, and in-flight performance of the Terwave Payloads. This role will support payload hardware development from initial concept through flight. The Senior Mechanical Engineer will work closely with Structures, Thermal, Electrical, and RF Engineers to develop RF components, phased-array and parabolic antennas, and related assemblies that meet high system performance requirements and can be manufactured at scale. Your role is to be the mechanical authority for turning antenna concepts into reality. This involves everything from the micro-packaging of Antenna-in-Package (AiP) modules to the large-scale structural integrity of reflector systems. You will collaborate daily with antenna engineers to ensure their RF designs can be built, tested, and withstand the rigors of launch and operation in space. Responsibilities Collaborate closely with RF and Electrical engineers to co-design and develop mechanical solutions for phased array antennas, reflector antennas, and their associated feed systems. Lead the mechanical design and layout of complex, multi-layer printed circuit boards (PCBs) and antenna substrates, ensuring compatibility with high-frequency RF performance requirements. Design and develop advanced Antenna-in-Package (AiP) solutions, focusing on micro-packaging and thermal management. Serve as the primary mechanical owner for Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Test (DFT), generating detailed fabrication packages (Gerbers, ODB++, 3D models, drawings) for external PCB and mechanical fab houses. Perform detailed structural, thermal, and vibration analysis on antenna assemblies—from the component level (AiP, RFICs) to the full array or reflector system—ensuring performance and survivability during launch and in the orbital environment. Conduct critical tolerance stack-up and sensitivity analyses to ensure that mechanical deviations (e.g., reflector surface RMS, feed alignment, PCB layer registration) do not degrade RF performance. Select and qualify advanced materials, including low-CTE metals (e.g., Invar), composites, and RF substrates, to maintain dimensional stability and electrical performance across extreme temperatures. Own the end-to-end mechanical design lifecycle in a CAD (e.g., Creo, SolidWorks) and PLM environment, from concept and detailed design to drawing creation, release, and manufacturing support. Minimum Qualifications B.S. in Mechanical Engineering or a related technical discipline with 7+ years of experience in the design of electronic or RF systems. Demonstrated experience in the mechanical packaging of electronic components, including PCB layout, substrate selection, and housing design. Proven ability to translate electrical schematics and RF design constraints into manufacturable mechanical packages for fabrication. Proficiency in 3D CAD software (e.g., Creo, SolidWorks) and Geometric Dimensioning and Tolerancing (GD&T). Strong understanding of manufacturing processes for PCBs and precision mechanical components (e.g., CNC milling, lamination, bonding). Proven experience working within interdisciplinary teams on highly integrated antenna packages, serving as the primary mechanical interface between RF/Antenna, Spacecraft Bus, and Thermal engineering teams to resolve competing design constraints and drive integrated solutions. Direct experience in the mechanical design of phased array antennas and reflector antenna systems for space or aerospace applications. Specific expertise in Antenna-in-Package (AiP) or System-in-Package (SiP) design, including familiarity with wire bonding, flip-chip, and BGA packaging technologies. Excellent communication and interpersonal skills, with a proven ability to work effectively in cross-functional teams. 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. in Mechanical Engineering or a related field. Experience creating and delivering complete fabrication data packages to external vendors and managing vendor communication. Experience with tolerance analysis that incorporates RF performance sensitivities. Experience with structural and thermal analysis and/or working with these teams to realize using Finite Element Analysis (FEA) tools (e.g., ANSYS, NASTRAN). Familiarity with the design challenges associated with mm-Wave frequencies (e.g., E-band, V-band). Knowledge of low-CTE materials (e.g., Invar, Graphite-Cyanate Ester) and their application in dimensionally stable structures. Experience with advanced manufacturing techniques such as Diffusion Bonding, Additive Manufacturing (3D printing) of RF components, or EDM. Compensation Range for: CA applicants is $145,188.00 - $203,263.20 WA applicants is $145,188.00 - $203,263.20 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 (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. 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. 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