Materials and Process Engineer III – Friction Stir Welding

BLUE ORIGIN•West Melbourne, FL

About The Position

This role is part of Blue Origin’s Upper Stage Development team and supports development and production operations for New Glenn, a reusable heavy-lift orbital launch vehicle. The engineer applies materials and process expertise, leadership, and quality-focused practices to support safe human spaceflight, with an emphasis on friction stir welding (FSW) for cryogenic tank structures. The position leads welding process qualification and development, oversees weld testing and material characterization, evaluates defects, and supports production welding of full-scale cryogenic tanks. It also works with design, manufacturing, quality, and supplier teams to establish materials and processes, resolve non-conformances, and deliver qualification documentation in accordance with launch schedules. Travel may be required for reviews, training, and tank production support.

Requirements

Bachelor’s degree or higher in materials engineering, welding engineering, mechanical engineering, or a related field.
At least 6 years of metallurgy experience, or at least 4 years with a relevant master’s degree, including deep knowledge of the relationships among composition, process, microstructure, and properties in aerospace materials; aluminum alloys are preferred.
At least 5 years of experience defining and qualifying welding processes, including fusion and/or solid-state welding.
Experience developing and executing material characterization plans, including mechanical testing, environmental testing, and material compatibility analysis.
Experience supporting design and manufacturing teams in an aerospace environment, including preparing specifications, test reports, and design substantiation documentation.
Experience working with aerospace suppliers, including on-site engineering audits, supplier qualifications, and statistical process controls.
Strong interpersonal and organizational skills, with the ability to prioritize and manage small and large projects involving diverse internal and external customers.
Ability to earn trust, maintain positive and professional relationships, and contribute to an inclusive culture.
Must be a U.S. citizen or national, U.S. permanent resident, or lawfully admitted into the United States as a refugee or granted asylum.

Nice To Haves

Expertise in friction stir welding of aluminum and/or aluminum-lithium alloys for aerospace applications.
Past experience as an aerospace Materials and Processes engineer.
Experience sourcing, analyzing, manufacturing, and testing aerospace-grade materials such as aluminum, nickel alloys, titanium, stainless steel, and other exotic alloys.
Working knowledge of basic statistical analysis to generate design allowables.
Knowledge of material behavior and compatibility in cryogenic tank systems.
Track record developing engineering requirements and work instruction documents.

Responsibilities

Lead welding process qualification, development, documentation, and internal and external readiness reviews.
Oversee metallographic and mechanical testing of welds and weld samples, and evaluate materials characterization data or nondestructive testing results.
Evaluate weld defects and recommend improvement plans or repair procedures.
Collaborate with cross-functional teams selecting materials, manufacturing processes, and suppliers for aerospace hardware.
Work with quality assurance and engineering teams on timely disposition and documentation of non-conformances involving tank structure defects.
Travel as needed for reviews, training, and tank production support activities.
Define material test plans for design value generation, source testing, and evaluate test data to develop statistics-based design values.
Support production welding of full-scale cryogenic tanks and lead development and optimization of FSW processes to meet specification requirements.
Troubleshoot weld tool equipment as required.
Coordinate with tank production teams to provide timely floor support and ensure weld qualification deliverables meet the launch schedule.

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
Paid time off of up to four weeks per year, based on scheduled weekly hours
Up to 14 company-paid holidays
Depending on role type and job level, potential eligibility for benefits and bonuses based on individual contributions or company results; amounts and eligibility are not guaranteed.