Senior Encapsulation Process Engineer for Space Packaging

Blue Origin LLC; Washington; On-site; USD 145,000 - 203,000; Full time

Job summary

Blue Origin LLC is seeking an experienced encapsulation/process development engineer to own the lamination, edge sealing, and barrier packaging workflows for solar module encapsulation and space-ready devices.

You will qualify materials, design accelerated aging studies for space environments, and collaborate across teams to scale processes from lab to module size, ensuring hermeticity and reliability in demanding operating conditions.

Qualifications

• Minimum Qualifications: B.Sc. Chemical Engineering, Materials Science, Mechanical Engineering, or related field with 5+ years in encapsulation, lamination, or packaging process development for PV/OLED/flexible electronics.

Responsibilities

• Develop lamination processes for solar module encapsulation: temperature profiles, pressure schedules, atmosphere control, and cure protocols.
• Qualify encapsulant materials (EVA, POE, ionomer, silicone, TPU) for compatibility with device stack.
• Develop and validate thin-film encapsulation processes (PECVD, ALD barriers) with team members.
• Design accelerated aging studies for space and launch environments (humidity, thermal cycling, UV, radiation).
• Optimize edge-sealing processes (desiccant edge seals, laser sealing, UV-curable adhesives) for hermeticity.
• Establish inline process monitoring and acceptance criteria (optical inspection, leak testing, adhesion tests).
• Perform failure analysis on degraded modules; develop process docs, SPC, and CP studies.
• Scale encapsulation from coupon to full module; interface with vendors to specify lamination, sealing, and barrier tools.
• Collaborate with customers on broader solar array product team for at-scale integration.

Skills

Encapsulation process development

Lamination processes

Polymer processing

Accelerated aging test design

Process characterization tools

Qualification testing

Failure analysis

Scale-up to production

Equipment interfacing

Education

BSc in Chemical Engineering, Materials Science, Mechanical Engineering, or related field

Tools

DSC

TGA

DMA

peel testing

optical microscopy

moisture sensors

Job description

Blue Origin LLC is seeking an experienced encapsulation/process development engineer to own the lamination, edge sealing, and barrier packaging workflows for solar module encapsulation and space-ready devices.

You will qualify materials, design accelerated aging studies for space environments, and collaborate across teams to scale processes from lab to module size, ensuring hermeticity and reliability in demanding operating conditions.