Staff Mechanical Engineer, Spacecraft Engine

Astra • Alameda, CA

158d

About The Position

We are looking for a Staff Mechanical Engineer to lead the mechanical design and manufacturability of next-generation Hall-effect thrusters for spacecraft propulsion. This role is critical to ensuring that our propulsion systems not only achieve world-class performance and reliability in orbit but are also optimized for repeatable, cost-effective, and scalable production. The ideal candidate will blend deep expertise in mechanical design for extreme environments with a proven ability to drive design-for-manufacture (DFM) and design-for-assembly (DFA) principles into hardware that must survive launch and operate for years in space.

Requirements

• 5+ years of experience in mechanical design of aerospace hardware, including propulsion or high-reliability spacecraft systems
• Deep expertise in mechanical design for spaceflight hardware, including structural, thermal, and materials considerations
• Proven track record of applying DFM/DFA principles to aerospace hardware that transitioned successfully into production
• Proficiency with CAD and analysis tools (e.g., SolidWorks, Creo, NX, ANSYS, or equivalent)
• Hands-on experience with qualification testing for flight hardware (vibration, shock, thermal-vacuum)
• Familiarity with spaceflight standards and certification processes (NASA, ESA, ECSS, MIL-STD, or equivalent)
• Strong communication and leadership skills, with the ability to influence system-level decisions and mentor teams
• Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a related field

Nice To Haves

• Direct experience with electric propulsion hardware, particularly Hall-effect thrusters or ion engines
• Background in high-temperature materials, ceramics, or coatings for plasma-facing components
• Experience scaling hardware from engineering development units to flight production at quantity
• Familiarity with additive manufacturing or other advanced manufacturing techniques for propulsion systems
• Previous experience serving as a mechanical lead or system architect for flight hardware

Responsibilities

• Thruster Mechanical Architecture: Own and develop the structural and thermal design of Hall-effect thruster components including discharge channels, magnetic circuits, and electrode assemblies.
• Design for Manufacturability: Drive DFM/DFA practices across the thruster hardware, ensuring scalability from prototype to high-volume production.
• Material & Process Selection: Evaluate and specify advanced materials, coatings, and joining methods compatible with high-temperature plasma environments and long-duration missions.
• Analysis & Verification: Perform structural, thermal, and dynamic analyses to validate designs against launch loads, thermal cycles, and space environmental factors.
• Supplier Engagement: Collaborate with manufacturing and supply chain partners to mature designs, resolve producibility challenges, and qualify vendors.
• Testing & Qualification: Define and support mechanical testing campaigns (vibration, shock, thermal-vacuum, life testing) to ensure compliance with flight requirements.
• Cross-functional Collaboration: Work closely with plasma physics, electrical, and systems engineering teams to balance mechanical design with thruster performance, integration, and mission needs.
• Leadership: Mentor mechanical and propulsion engineers, review critical designs, and act as a subject matter expert in manufacturable spacecraft propulsion hardware.
• Continuous Improvement: Lead efforts to simplify, standardize, and modularize thruster designs for reduced cost, improved reliability, and faster production cycles.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 251-500 employees