Senior Thermal Engineer - Constellations

Blue Origin; Reston (VA); On-site; USD 140,000 - 190,000; Full time

Job summary

Blue Origin is seeking a Senior Thermal Engineer to lead the thermal design and analysis for satellite payloads and in-space constellation solutions. This role focuses on ensuring reliable high-power payload performance in LEO through advanced thermal management and cross-disciplinary integration.

The ideal candidate will drive models, interfaces, and qualification strategies and address fatigue and manufacturability across multiple programs, delivering reliable space hardware.

Qualifications

• Deep expertise in thermal management of space-qualified hardware, RF / Opto-electrical components, radar systems, and/or specialized payload types.
• Ability to drive cross-disciplinary design integration across payload, mechanical, avionics, and power subsystems.
• Experience leading thermal design for satellite payloads and in-space constellation programs.

Responsibilities

• Lead thermal design & analysis for satellite-based, high-power payloads and associated power electronics.
• Develop detailed thermal models using 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 performan

Skills

Thermal design

Thermal analysis

Thermal modeling

Thermal Desktop

SINDA/FLUINT

Heat pipes

Radiators

Loop heat pipes

Cold plates

Electronics cooling

Tools

Thermal Desktop

SINDA/FLUINT

Job description

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!

The role is part of the In-Space Systems business unit, which is focused on addressing two of the most compelling challenges in spaceflight today: space infrastructure and increasing mobility on-orbit.

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

• Location: This role can be based at any of the following Blue Origin locations: Denver, CO; Los Angeles, CA; Space Coast, FL; Reston, VA; Huntsville, AL; or Kent, WA (Seattle area).
• 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

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 performan