Senior Structural and Thermal Engineer - Optical Systems - TeraWave

Blue Origin • El Segundo, CA

1d

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. As a Structural & Thermal Engineer focused on STOP analysis, you will serve as the analytical backbone, ensuring our optical systems achieve peak performance from launch through on-orbit operations. You will own the integrated Structural, Thermal, and Optical Performance (STOP) analysis, and your models will directly guide critical opto-mechanical design decisions. The Mission: You will be the engineer who answers the critical question: "Will this system meet its optical performance requirements in space?" Through high-fidelity modeling, simulation, and rigorous uncertainty quantification, your analyses will provide the foundation of confidence that our designs are robust against the challenges of launch and the space environment. Special Mentions: Relocation assistance may be available for this position Travel expectations: Occasional travel may be for test campaigns and design reviews

Requirements

• Bachelor's degree in Mechanical Engineering , Aerospace Engineering, or a related field with 7+ years of relevant experience (M.S./Ph.D. preferred)
• Expertise in FEA for precision space structures, with proven experience in modal/dynamic analysis, random vibration, and thermoelastic distortion
• Deep understanding of passive and active thermal control systems and analysis for space applications
• Strong skills in uncertainty quantification, including probabilistic analysis, Monte Carlo methods, and sensitivity studies
• Proficiency with relevant analysis software (FEA: Nastran, Ansys, or Abaqus; Thermal: Thermal Desktop, SINDA/FLUINT, or similar)

Nice To Haves

• Mastery of coupling structural/thermal models with optical design tools ( Zemax , Code V, or similar)
• Experience with the unique challenges of telescopes, complex optics, or gimbaled systems
• Background in designing low-jitter structures, including the use of isolation systems or damping
• Experience with test correlation, including pre-test analysis and post-test model updates for TVAC or vibration campaigns
• Proficiency in a scripting language (Python, MATLAB) for data analysis, process automation, and parametric studies

Responsibilities

• Integrated STOP Analysis Perform coupled STOP analysis by integrating your structural and thermal predictions with the optical design model (via ray-tracing or sensitivity matrices)
• Derive, allocate , and close optical performance budgets (e.g., alignment, WFE) in collaboration with optical and mechanical engineers
• Bound system sensitivities to environmental and structural inputs (temperature gradients, launch loads) and propose effective design mitigations
• Structural Modeling & Jitter Analysis Build and maintain high-fidelity Finite Element (FEA) models to analyze modal response, random vibration (PSD), shock, and quasi-static loads
• Analyze and mitigate the effects of gravity release and mount preloads on optical alignment and surface figure
• Quantify structural stiffness and jitter transfer functions to ensure fine-pointing stability and performance
• Thermal Modeling & Control Develop detailed thermal models to simulate radiation, conduction, and active thermal control systems (heaters, straps, radiators)
• Manage thermal dissipation and ensure optical stability across all operational and survival modes, including eclipse transitions and slews
• Translate thermoelastic distortions from your models into quantified impacts on optical performance, such as focus shifts and alignment drift
• Model Validation & Test Correlation Define a comprehensive model validation plan, specifying instrumentation requirements (accelerometers, thermocouples, strain gauges) for environmental testing
• Correlate analytical models with thermal-vacuum (TVAC) and vibration test data, iterating as needed to improve predictive accuracy
• Develop and present the definitive evidence package for system feasibility, including model pedigree, uncertainty analysis, and sensitivity studies

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.
• Dependent on role type and job level, employees may be eligible for benefits and bonuses based on the company's intent to reward individual contributions and enable them to share in the company's results, or other factors at the company's sole discretion.

What This Job Offers

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