Engines Materials & Process - Casting Engineer III

BLUE ORIGIN • Huntsville, WA

4d • $121,023 - $169,432 • Onsite

About The Position

This role is part of the Blue Origin Engines business unit, where our focus is the design, development, manufacturing, and testing of engines and propulsion systems. Built for multiple uses, our family of engines is powering the next generation of rockets for commercial, civil, national security, and human spaceflight. This is a unique role, which will span Materials and Process Engineering and aspects of casting producibility, where you will help drive manufacturable casting designs to improve first-time yields, followed by qualifying the hardware.

Requirements

• B.S. or higher degree in Materials Science & Engineering, Chemical Engineering, Mechanical Engineering or related field
• Minimum 5 years process engineering experience with metal casting
• Ability and willingness to work onsite, with up to 20% of the time (or as needed) being in or traveling to Arlington, WA and the balance being in Kent/Renton, WA or Huntsville, AL
• Experience with basic gating/riser design, investment or molding process, melt and cast process
• Metallurgical expertise with material systems used in the aerospace industry, such as Ni-based alloys, Ti-based alloys, oxygen-compatible alloys
• Experience with part and process qualification and developing process controls
• Ability to collect and analyze data and present results in a meaningful format
• 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.

Nice To Haves

• Metallurgical understanding of heat treatment and welding for Nickel-based superalloys
• Experience in CAD software, such as CREO or SolidWorks
• Expertise with casting process simulation software (Magmasoft or ProCAST)
• Expertise in statistical process control for wax, shell, cast, and dimensions
• Experience with and knowledge of investment/shell process and slurries.
• Ability to drive process control and improvements
• Experience with auditing casting and associated processes.
• Expertise with driving corrective actions.
• Experience with failure and forensic analysis of aerospace hardware
• Understanding of aerospace quality standards and Quality Management Systems

Responsibilities

• Support and provide oversight for design intent related to casting process development and process control at manufacturing sites.
• Influence, establish, and control process envelopes for gating design, shell, mold prep, and melt/pour process steps such that Engineering requirements are met.
• Influence Design for Manufacturability (DFM) such that cast hardware can be produced at rate with minimal rework
• Review casting part drawings, and collaborate with design, analysis, manufacturing on the implementation of design requirements into production.
• Own casting part qualification; collaborate with design, analysis, manufacturing to align on testing scope.
• Complete Materials & Processes Engineering responsibilities on First Article Qualifications, non-conformances, repairs and continuous improvement projects.
• Find opportunities for new or improved material and process development, coordinate test campaigns, provide program updates to Product Team Leads.
• Participate in the development of internal engineering and quality processes to standardize and accelerate material evaluation, implementation, and qualification procedures.

Benefits

• Relocation provided
• 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.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior