Senior Reliability Engineer – Hardware Systems

BLUE ORIGIN • Seattle, WA

2d • $197,529 - $276,540

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! Blue Origin is pioneering the future of space-based communications with TeraWave, a revolutionary satellite communications network designed to deliver symmetrical data speeds of up to 6 Tbps anywhere on Earth. This multi-orbit constellation will consist of optically interconnected satellites in low Earth orbit (LEO) and medium Earth orbit (MEO), providing enterprise-grade connectivity for critical operations worldwide. We are seeking a Senior Reliability Engineer to own the reliability strategy, testing framework, and environmental validation for our next-generation satellite user terminal hardware. In this role, you will design and execute advanced testing protocols to ensure high-power, electronically steered systems perform reliably in extreme outdoor environments. You will collaborate closely with electrical, mechanical, and RF teams to identify design vulnerabilities, predict product lifetime, and drive hardware improvements prior to mass production.

Requirements

• Bachelor’s degree in mechanical engineering, Electrical Engineering, Materials Science, or Reliability Engineering.
• 7+ years of experience in hardware reliability engineering, validation testing, or failure analysis for outdoor electronics, aerospace hardware, automotive systems, or telecom infrastructure.
• Direct experience operating environmental chambers, vibration/shaker tables, and electronic thermal cycle systems.
• Proficiency with reliability statistics and software tools (e.g., ReliaSoft, Minitab, JMP) to analyze life data using Weibull distributions and accelerated testing models.
• Proven track record of leading cross-functional DFMEA sessions and translating failure risks into concrete hardware design modifications.

Nice To Haves

• Master’s degree in mechanical engineering, Electrical Engineering, Materials Science, or Reliability Engineering.
• Understanding of long-term environmental degradation, micro-cracking, and moisture absorption in RF-transparent plastics (e.g., ASA, Polycarbonate, Composites).
• Knowledge of failure mechanisms in High-Density Interconnect (HDI) PCBs, such as thermal fatigue of solder joints, tin whiskers, or board warpage under dynamic thermal loads.
• Familiarity with telecom and aerospace environmental standards, such as MIL-STD-810, IEC 60068, GR-487, or automotive AEC-Q100.

Responsibilities

• Design and execute reliability test plans, including Highly Accelerated Life Testing (HALT), Highly Accelerated Stress Screen (HASS), and Environmental Stress Screening (ESS).
• Set up and oversee physical testing programs for weather-proofing, including ingress protection (IP67+ water/dust), UV exposure degradation, solar radiation, salt fog corrosion, and extreme thermal cycling.
• Lead deep-dive root cause failure analysis on electrical components, PCB solder joints, materials, and structural interfaces using tools like X-ray, microscopy, and cross-sectioning.
• Ownership of DFMEA (Design Failure Mode and Effects Analysis).
• Develop physics-of-failure models to predict product lifetime, Mean Time Between Failures (MTBF), and warranty risks.
• Collaborate with mechanical engineers on FEA/CFD results and electrical engineers on Power Delivery Network (PDN) profiles to target specific high-stress areas (thermal hotspots, high vibrational loads) during physical testing.
• Work with external test labs to validate regulatory compliance standards and ensure component suppliers meet strict quality and reliability baselines.

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.
• 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