Senior Opto-Mechanical Engineer - TeraWave

Blue Origin • El Segundo, CA

1d • Onsite

About The Position

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! This role is part of TeraWave, a satellite communications network designed to deliver symmetrical data speeds of up to 6 Tbps anywhere on Earth. This network will service tens of thousands of enterprise, data center, and government users who require reliable connectivity for critical operations. SENIOR OPTO-MECHANICAL ENGINEER Location: Longmont, CO (Onsite) Role Summary: The Senior Opto-Mechanical Engineer will serve as the technical lead for the mechanical design, structural analysis, and line-of-sight (LOS) stability of optical communication systems for space environments. This role is critical to a production line. You will own the mount/cell design, Structural-Thermal-Optical Performance (STOP) analysis, and environmental qualification for an optical payload. Special Mentions: This position requires relocation to Longmont, CO Travel expectations: Up to 10% travel may be for technical reviews and test campaigns

Requirements

• BS in Mechanical or Aerospace Engineering (MS preferred) and 10+ years of professional experience in opto-mechanical engineering for space payloads
• Proven expertise in structural FEA (ANSYS/Nastran) for modal, random vibration, and shock analysis
• Expert proficiency in CAD (PTC Creo or NX) for complex opto-mechanical assemblies and production drawings
• Strong understanding of GD&T, tolerance analysis, and DFM/DFA principles
• Hands-on experience with interfaces, kinematic mounts, and contamination-sensitive optical hardware

Nice To Haves

• Expertise in STOP analysis and athermalization techniques
• Experience with fiber optics, pigtails, and active alignment systems
• Prior flight hardware qualification and environmental test campaign leadership
• Knowledge of ISO 9001/AS9100 and spaceflight documentation practices

Responsibilities

• Opto-Mechanical Design Leadership Lead mechanical design of sub-assemblies, including telescope mounts/cells, benches, kinematic interfaces, and fiber management systems
• Design for maximum stability against dynamic launch loads (random vibration, shock) and on-orbit thermal cycling
• Define datum/fiducials, build-to tolerances, and align-to tolerances; generate interface control drawings (ICDs) and production-ready drawings with comprehensive GD&T
• Design for Manufacturing (DFM) and Production Integration Drive DFM and Design for Assembly (DFA) principles into the hardware design from the start to enable reliable, cost-effective production
• Interface with internal manufacturing, tooling, and GSE teams to optimize assembly sequences, reduce part count, and simplify fixtures
• Support tolerance stack-ups and dimensional metrology planning to ensure designs meet production quality
• Structural-Thermal-Optical Performance (STOP) Analysis Perform detailed STOP analysis using Finite Element Analysis (ANSYS/Nastran) to model and predict effects of thermal loads, vibration, and static loads on optical performance (Wavefront Error, MTF, LOS jitter) with Optical Engineer
• Own the LOS stability budget; conduct sensitivity studies for mount compliance, CTE mismatch, thermal gradients, and structural damping
• Optimize stiffness/mass ratios and modal separation strategies to survive vibe/shock while protecting WFE/MTF performance
• Partner with the Thermal & Materials Engineer on athermalization strategies for interfaces
• Verification, Qualification, and AI&T Support Support environmental test campaigns (TVAC, random vibration, shock) and lead root-cause analysis for any structural or mechanical anomalies
• Support hands-on optical alignment and integration in a Class 100/1000 cleanroom, providing mechanical expertise to resolve fit and function issues

Benefits

• 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.

What This Job Offers

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