Avionics Harness Mechanical Design & Analysis Engineer II

Blue Origin•Huntsville, AL

About The Position

This role is part of Blue National Security (BNS), which designs, develops, and delivers launch and spacecraft systems for national security missions. The engineer will design, analyze, integrate, and test avionics routed interconnect systems for spacecraft in collaboration with electrical, mechanical, structural, manufacturing, and systems engineers. The work focuses on reliable electrical harness installations for harsh space environments. The engineer will own the mechanical design and analysis of electrical harness routing, installation hardware, and support brackets. The role includes developing 3D routed harness models, electrical interconnect diagrams, installation and flattened harness drawings, bracket drawings using GD&T, and associated technical data packages. Structural FEA and engineering hand calculations are used to validate harness support hardware and demonstrate compliance with structural, vibration, and interface requirements. The position calls for strong technical judgment, attention to detail, quality, and a commitment to safe human spaceflight.

Requirements

B.S. degree in Mechanical, Aerospace, Electrical, Electromechanical Engineering, or a related technical field.
At least 2 years of experience designing and integrating wire harnesses for spacecraft, launch vehicles, aircraft, or similar high-performance systems.
Experience with 3D CAD-based electrical and mechanical routing.
Experience creating harness schematics, system interconnect diagrams, block interconnect diagrams, or wiring interconnect diagrams.
Experience designing harness installation hardware and support brackets.
Working knowledge of GD&T implementation and tolerance analysis in accordance with ASME Y14.5.
Experience performing structural FEA and engineering hand calculations for brackets, supports, fasteners, or similar mechanical hardware.
Knowledge of aerospace structural design criteria, margins of safety, material allowables, and fastener analysis.
Ability to interpret mechanical and electrical interface requirements and integrate harnesses within complex vehicle assemblies.
Familiarity with applicable harness workmanship and design standards, including IPC/WHMA-A-620 and NASA-STD-8739.4.
Strong mechanical design, analytical, problem-solving, and technical communication skills.
Ability to be self-directed, manage multiple priorities, and work effectively across engineering disciplines.
Applicants 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.

Nice To Haves

Experience with Creo and Creo Routed Systems; these are preferred for 3D CAD-based routing.
Experience with Creo Schematics, Zuken, Windchill, or similar CAD and PLM tools.
Experience with ANSYS or comparable structural FEA software.
Experience developing free-body diagrams and hand calculations for launch, random vibration, shock, fatigue, and fastener loading.
Experience routing and installing RF coaxial cable, high-speed data cables, fiber optics, or other specialty interconnects.
Experience designing lightweight sheet-metal, machined, or additively manufactured harness brackets.
Experience supporting environmental testing, including vibration, shock, thermal vacuum, and qualification or acceptance testing.

Responsibilities

Develop and analyze electrical harness designs as part of a cross-disciplinary engineering team.
Create and maintain system interconnect diagrams, block interconnect diagrams, wiring interconnect diagrams, and schematics.
Design and integrate 3D electrical harness routing on spacecraft vehicle assemblies.
Develop 2D flattened harness drawings, harness installation drawings, detail drawings, and assembly drawings.
Design harness support hardware, including brackets, clips, clamps, standoffs, shields, and related mounting provisions.
Apply GD&T in accordance with ASME Y14.5 to harness hardware, brackets, installation interfaces, and drawings.
Perform structural FEA and engineering hand calculations for harness brackets and support hardware, including static strength, stiffness, fastener loads, vibration response, and margins of safety.
Conduct design and analysis trade studies to optimize harness routing, support spacing, installation accessibility, mass, manufacturability, and structural performance.
Select and integrate harness components, including connectors, backshells, wire, cable, RF coax, shielding, sleeving, clamps, and attachment hardware.
Support electrical and mechanical configuration management, including engineering bills of material and product lifecycle management.
Evaluate harness designs for bonding, grounding, shielding, separation, bend radius, thermal considerations, and protection from abrasion or mechanical damage.
Define and verify design requirements through analysis, inspection, test, and similarity.
Support test planning, test execution, data review, nonconformance resolution, and hardware troubleshooting.
Collaborate with manufacturing and integration teams to ensure designs are producible, inspectable, and installable.
Communicate design and analysis results through technical reports, design reviews, and certification documentation.

Benefits

Medical insurance
Dental insurance
Vision insurance
Basic and supplemental life insurance
Paid parental leave
Short- and long-term disability
401(k) with company match of up to 5%
Education Support Program
Stock options for regular employees working at least 20 hours per week
Up to four weeks of paid time off per year based on weekly scheduled hours
Up to 14 company-paid holidays
Employees may be eligible for benefits and bonuses depending on role type, job level, and other factors; amounts and eligibility are not guaranteed.