Propulsion Engineer II, Thermal Systems

BLUE ORIGIN•Huntsville, AL

5d•$99,201 - $138,880

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. As part of a hardworking team of engineers, you will design, analyze, and optimize the next generation of heat exchangers for demanding thermal‑fluid environments. You will work with cross‑functional teams to develop innovative, high‑effectiveness, low‑pressure‑drop thermal solutions and to mature them from concept through qualification. You will be responsible for defining heat exchanger cores, headers, manifolds, and assemblies to support fabrication, testing, and production. A successful candidate will apply their knowledge across multiple applications involving heat transfer between fluids and phases, demonstrating versatility and technical depth as designs advance through successive iterations.

Requirements

Bachelor's degree in Mechanical Engineering or related field
Minimum of 2 years of relevant industry experience
Strong application of first principles in heat transfer, fluid mechanics, thermodynamics, and materials science
Experience with heat exchangers, high‑temperature or cryogenic thermal systems, or high‑pressure fluid systems
Knowledge of thermal expansion management and thermal stress analysis
Experience with test data analysis and correlation of test results to predictions
Solid troubleshooting skills for complex thermal‑fluid systems
Familiarity with relevant industry standards and codes (ASME BPVC, TEMA, API, etc.)
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

Master's degree in Mechanical Engineering with focus on thermal sciences or fluid systems
5+ years of relevant industry experience
Experience designing and iterating on multiple heat exchanger types (e.g., tube‑and‑shell, plate‑fin, printed‑circuit/PCHE, regenerative cooling channels, cryogenic and tank‑pressurization heat exchangers)
Working knowledge of heat exchanger sizing and rating methods (LMTD/ε‑NTU), pressure‑drop optimization, and flow distribution
Familiar with CFD and FEA simulation tools for thermal‑fluid and thermal‑structural analysis
CAD proficiency (NX, CATIA, or similar software)
Experience with single‑phase and two‑phase (boiling/condensing) heat transfer
Experience with design for manufacturing and assembly of complex fluid systems, including brazing, welding, and additive manufacturing of heat exchanger cores
Understanding of fouling, thermal fatigue, and life‑cycle considerations in heat exchanger design
Familiarity with radiation heat transfer analysis and thermal protection systems
Background in aerospace, energy generation, or heavy industrial applications

Responsibilities

Lead design, development, and testing of heat exchangers and related thermal‑fluid systems, driving successive design iterations toward improved effectiveness, cost, and manufacturability
Develop system requirements, specifications, and design documentation for heat exchanger cores and assemblies
Design and optimize heat exchanger geometries and components — including cores, headers, manifolds, tube sheets, and mounting/support structures — balancing thermal effectiveness against pressure drop, mass, and volume
Select appropriate materials for applications considering thermal cycling, creep, fatigue, and corrosion resistance
Create detailed engineering drawings and models using 3D CAD software with proper GD&T per ASME Y14.5 standards
Lead and participate in component and system‑level testing, including test planning, execution, and thermal/hydraulic data reduction and correlation to analytical predictions
Troubleshoot design and operational issues (e.g., thermal stress, flow maldistribution, fouling, leakage) with calculated risk assessment
Collaborate with manufacturing and quality teams to ensure producibility of designs, including brazed, welded, and additively manufactured cores
Interface with various engineering disciplines to ensure proper thermal and system integration