Senior Thermal Engineer – Constellations

Blue Origin; Denver (CO); On-site; USD 144,000 - 202,000; Full time

Benefits offered by this job

Relocation assistance

Up to 25% travel

Job summary

Blue Origin in Colorado is seeking a Senior Thermal Engineer to lead the thermal design and analysis for satellite payloads and in‑space constellation solutions. You will develop thermal models, manage interfaces, and collaborate with payload, mechanical, power, and systems teams to ensure reliability across mission profiles and environmental conditions.

The role seeks deep experience with spaceborne thermal design, radiation heat transfer, and qualification testing, with opportunity for

Qualifications

• Bachelor's degree in mechanical engineering, aerospace engineering, physics, or related field.
• 7+ years of experience in thermal engineering for aerospace systems and/or high‑power electronics.
• Experience with spaceborne thermal design, vacuum environments, radiation heat transfer, and flight hardware qualification.
• Experience with thermal modeling tools (Thermal Desktop, SINDA/FLUINT, ANSYS Icepak).
• Knowledge of environmental standards (NASA, ESA, MIL‑STD) and qualification testing.
• Ability to obtain and maintain TS/SCI clearance.

Responsibilities

• Lead thermal design & analysis for satellite‑based, high‑power payloads and associated power electronics.
• Develop thermal models using tools like Thermal Desktop, SINDA/FLUINT, or ANSYS Icepak.
• Define and manage thermal interfaces across payload subsystems and radiators.
• Perform transient and steady‑state thermal analyses for mission profiles and environmental conditions.
• Develop thermal architecture for reusable bus/payload configurations across production blocks.
• Define thermal model correlation strategy with limited test data and extend to production blocks.
• Address LEO thermal cycling fatigue on joints, solder, TIMs, and coatings.
• Drive manufacturability of thermal hardware and parametric modeling workflows.
• Evaluate COTS components and manage heater power budget as a fleet driver.
• Support design‑for‑demise and material selection for disposal risk.

Skills

7+ years experience

Spaceborne thermal design

Thermal modeling tools

Environmental standards

TS/SCI clearance

US citizenship/perm resident

Education

Bachelor's degree in mechanical/aerospace/physics

Tools

Thermal Desktop

SINDA/FLUINT

AN SYS Icepak

Job description

Applications will be accepted on an ongoing basis until the requisition is closed.

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 Blue National Security (BNS), where our focus is the design, development, and delivery of launch and spacecraft systems for national security missions. Through Blue Ring, our all-in-one, high-powered hybrid solar-electric and chemical-propelled spacecraft, we provide unmatched mission maneuverability, versatility, and capacity at dramatically lower-profile costs.

This role is part of the Blue National Security business unit, which is focused on delivering advanced space-based capabilities in support of national security, civil, and commercial missions. Within the Advanced Systems organization, the multi-disciplinary Future Concepts & Capabilities team operates at the forefront of systems engineering, formulation, and architecture, developing next‑generation space systems that address the most demanding and consequential challenges in the space domain.

We are seeking a Senior Thermal Engineer to lead the thermal design and analysis for both satellite payloads and integrated in‑space constellation solutions. This role is central to ensuring reliable performance of a diverse array of high‑power payload systems operating in LEO and other orbital regimes. The ideal candidate brings deep expertise in thermal management of space‑qualified hardware, RF / Opto‑electrical components, radar systems, and/or specialized payload types, along with the ability to drive cross‑disciplinary design integration across payload, mechanical, avionics, and power subsystems.

If you’re looking for novel challenges and rewarding work, come join a team pushing the boundaries of space system design to solve the defense and civil domains’ toughest problems!

Special Mentions

• Relocation: Relocation assistance is available for candidates relocating to one of the primary Blue Origin office locations.
• Travel: Up to 25% travel may be required depending on work location and program needs.

Responsibilities Include But Are Not Limited To

• Lead thermal design & analysis for satellite‑based, high‑power payloads and associated power electronics.
• Develop detailed thermal models using tools such as "Thermal Desktop", SINDA/FLUINT, or equivalent, covering conduction, radiation, and convection regimes as appropriate.
• Define and manage thermal interfaces across payload subsystems, including radiators, heat pipes, loop heat pipes, cold plates, and structural elements.
• Perform transient and steady‑state thermal analyses to validate performance under mission profiles, including peak duty cycles, eclipse transitions, and worst‑case environmental conditions.
• Develop thermal architecture for common bus/payload configurations reused across a production block, including tailoring for orbit plane, beta angle range, and payload variant.
• Select and defend the appropriate thermal qualification, margin, and acceptance approach (e.g., protoflight, workmanship‑only TVAC on subsequent units, thermal cycling screening, lot acceptance sampling) based on build rate, mission class, and design life; tailor requirements per SMC‑S‑016 / MIL‑STD‑1540 as applicable.
• Define thermal model correlation strategy under limited test data, extending correlated models across the rest of a production block.
• Address LEO thermal cycling fatigue over high cycle counts (~5,000+ eclipse cycles/year) on joints, solder, TIMs, and coatings across design life.
• Drive design‑for‑manufacturability of thermal hardware at rate (e.g., MLI touch labor, coating repeatability, TIM dispensing, heater and thermostat installation), leveraging parametric or automated thermal modeling workflows to support rapid trades.
• Evaluate COTS or commercial‑grade thermal components where mission class permits, and manage heater power budget as a fleet‑level EPS driver, trading heater sizing against battery and array mass.
• Support design‑for‑demise and material selection for disposal casualty risk (ODMSP).
• Assess manufacturability, cost, and schedule impact of thermal hardware choices (radiators, heat pipes, loop heat pipes, cold plates) for production at scale.
• Support thermal design and analysis concurrently across multiple constellation and payload programs, prioritizing effort against shifting schedules and design maturity.
• Collaborate closely with payload subject matter experts, mechanical, power, and systems engineering teams to ensure thermal constraints are integrated into payload element layout and packaging.
• Establish thermal requirements, margins, and verification plans aligned with mission reliability and lifetime goals.
• Drive thermal design trades balancing performance, mass, power consumption, manufacturability, and cost for both space and ground systems.
• Contribute to major technical design reviews and serve as a key technical authority for the thermal system.
• Mentor junior engineers and contribute to organizational best practices in thermal engineering.

Minimum Qualifications

• Bachelor's degree in mechanical engineering, aerospace engineering, physics, or related field.
• 7+ years of experience in thermal engineering for aerospace systems and/or high‑performance electronics.
• Demonstrated experience with spaceborne thermal design, including vacuum environments, radiation heat transfer, and flight hardware qualification.
• Experience with thermal modeling tools (e.g., "Thermal Desktop", SINDA/FLUINT, ANSYS Icepak, or equivalent).
• Knowledge of materials, coatings, and thermal interface technologies suitable for space systems.
• Familiarity with environmental standards (e.g., NASA, ESA, MIL‑STD) and qualification testing.
• Exceptional communication skills, with a demonstrated ability to influence and guide multidisciplinary teams.
• Ability and willingness to obtain and maintain a TS//SCI security clearance.
• Must be a U.S. citizen or national, U.S. permanent resident (current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Preferred Qualifications

• Master's or PhD degree in mechanical engineering, aerospace engineering, physics, or related field.
• Active TS//SCI clearance.
• Experience supporting capture and proposal efforts for new business opportunities, including contributing technical content and solutions to winning pursuits.
• Background in space‑based antenna systems or similar high‑power payload systems.
• Experience with thermal management of high‑power‑density electronics such as T/R modules, phased array apertures, or laser communication terminals.
• Experience with advanced cooling techniques, including loop heat pipes, vapor chambers, and liquid cooling systems.
• Experience on a proliferated LEO or other high‑rate satellite program.
• Experience with thermal cycling / ESS / HALT‑HASS‑style screening, including safety‑of‑screen or damage accumulation analysis.

Base Pay Range For

• VA applicants is $156,802.00 - $219,522.45 CO applicants is $144,179.00 - $201,849.90

Culture Statement

Don’t meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.

Export Control Regulations

Applicants for employment at Blue Origin must be a U.S. citizen or national, U.S. permanent resident (i.e. current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Background Check

• Required for all positions: Blue’s Standard Background Check
• Required for Certain Job Profiles: Defense Biometric Identification System (DBIDS) background check if at any time the role requires one to be on a military installation
• Required for Certain Job Profiles: Drivers who operate Commercial Motor Vehicles with a Gross Vehicle Weight (GVW), Gross Vehicle Weight Rating (GVWR) or combination of power unit and trailer that meets or exceeds 10,001 lbs. and/or transports placardable amounts of hazardous materials by ground in any vehicle on a public road while in commerce, may be subject to additional Federal Motor Carrier Safety Regulations including: Driver Qualification Files, Medical Certification (obtained before onboarding), Road Test, Hours of Service, Drug and Alcohol Testing, vehicle inspection requirements, CDL requirements (if applicable) and hazardous materials transportation/shipping training.
• Required for certain Job Profiles: Ability to obtain and maintain Merchant Mariner Credential, which includes pre‑employment and random drug testing as well as DOT physical

Benefits

• Benefits include: 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.
• 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. Bonus amounts and eligibility are not guaranteed and subject to change and cancellation. Please check with your recruiter for more details.

Equal Employment Opportunity

Blue Origin is proud to be an Equal Opportunity/Affirmative Action Employer and is committed to attracting, retaining, and developing a highly qualified and dedicated work force. Blue Origin hires and promotes people on the basis of their qualifications, performance, and abilities. We support the establishment and maintenance of a workplace that fosters trust, equality, and teamwork. We provide all qualified applicants for employment and employees with equal opportunities for hire, promotion, and other terms and conditions of employment, regardless of their race, color, religion, sex, sexual orientation, gender identity, national origin/ethnicity, age, physical or mental disability, genetic factors, military/veteran status, or any other status or characteristic protected by federal, state, and/or local law. Blue Origin will consider for employment qualified applicants with criminal histories in a manner consistent with applicable federal, state, and local laws, including the Washington Fair Chance Act, the California Fair Chance Act, the Los Angeles Fair Chance in Hiring Ordinance, and other applicable laws. For more information on "Know Your Rights," please see here.

Affirmative Action and Disability Accommodation

Applicants wishing to receive information on Blue Origin’s Affiliation Action Plans, or applicants requiring a reasonable accommodation in order to participate in the application and/or interview process, please contact us at [e-mail]. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.