Sr. TCA Mechanical Design Engineer
About The Position
Cowboy Space Corp. is building the infrastructure to power and connect the orbital economy. Our satellites operate in Low Earth Orbit to collect sunlight and enable a new class of capabilities—from powering on-orbit compute, to transmitting energy via infrared lasers (space-to-earth and space-to-space), to delivering secure, high-bandwidth optical data. By rethinking how energy and data are generated and distributed in space, we’re unlocking entirely new ways to operate both in orbit and on Earth. Founded in 2024 by Baiju Bhatt (co-founder of Robinhood), Cowboy Space Corp. is backed by leading investors and built by a team from top aerospace and defense organizations. We’re moving quickly to solve complex technical challenges and build a new category of space infrastructure. About the Role: We are seeking a Senior TCA Mechanical Design Engineer with deep expertise in manufacturing processes, tooling design, and specialized fabrication methodologies to support rocket engine injector, combustion chamber, and nozzle development. The ideal candidate combines advanced mechanical design capabilities with hands-on manufacturing expertise to drive rapid design/build/test cycles. This position is located onsite in the greater Seattle, WA area.
Requirements
- Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering
- Strong mechanical design proficiency with DFM/DFA emphasis
- Hands-on experience with CNC machining, welding/brazing, or additive manufacturing
- Technical proficiency in thermodynamics, fluid dynamics, and structural mechanics
Nice To Haves
- Rocket engine TCA component lifecycle ownership including production
- Design for Additive Manufacturing expertise
- Precision machining knowledge: 5-axis CNC, high-speed machining, Swiss machining
- Specialized joining expertise: vacuum brazing, electron beam/laser welding, friction stir welding
- Tooling design: fixtures, EDM electrodes, CMM/welding fixtures
- Ansys Mechanical, Fluent, or Thermal Desktop experience
- Advanced degree in engineering discipline
Responsibilities
- Own end-to-end TCA hardware lifecycle from requirements through manufacturing to flight qualification
- Lead mechanical design optimized for manufacturability, applying physics-based analysis
- Implement advanced manufacturing techniques: additive manufacturing, precision CNC machining, EDM, and specialized joining (e.g. laser welding, vacuum brazing, diffusion bonding)
- Design tooling, fixtures, and work-holding solutions for rapid development and repeatable production
- Develop and qualify manufacturing process parameters for novel materials and geometries
- Plan and execute hotfire test campaigns, analyze results, and lead rapid redesign efforts balancing performance with manufacturing constraints
Benefits
- Medical insurance
- Dental insurance
- Vision insurance
- 401(k) retirement savings plan
- Paid time off
- 10 paid holidays per calendar year
- Paid parental leave
- Relocation assistance
- Daily lunch in the office
- Fully stocked kitchen with beverages and snacks
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What This Job Offers
Job Type
Full-time
Career Level
Senior
