Senior Thermal Engineer – Constellations

Blue Origin LLC; Reston, Northern (VA, KY); Hybrid; USD 157,000 - 220,000; Full time

Benefits offered by this job

Relocation assistance

Up to 25% travel

Job summary

Blue Origin LLC seeks a Senior Thermal Engineer to lead thermal design and analysis for satellite payloads and integrated constellation systems. You will develop and validate thermal models, manage interfaces, and drive design decisions across payload, mechanical, avionics, and power teams.

The role requires strong experience with spaceborne thermal design, high-power electronics, and a collaborative, mission-focused mindset. Relocation assistance and up to 25% travel are offered.

Qualifications

• Bachelor's degree in mechanical engineering, aerospace engineering, physics, or related field required.
• Experience with spaceborne thermal design in vacuum environments and flight hardware qualification.
• Proficiency with thermal modeling tools (Thermal Desktop, SINDA/FLUINT, ANSYS Icepak) and materials/thermal interface tech.

Responsibilities

• Lead thermal design and analysis for satellite payloads and constellation hardware.
• Develop detailed thermal models covering conduction, radiation, and convection.
• Define thermal interfaces across subsystems and manage radiators, heat pipes, and cold plates.
• Perform transient/steady-state analyses for mission profiles and environmental conditions.
• Define thermal architecture for common bus/payload configurations and tailor for orbit and payload variants.
• Determine and defend qualification approaches and testing strategy per standards.
• Correlate models with limited test data and extend to production blocks.
• Address high-cycle thermal fatigue and manufacturability of thermal hardware.
• Collaborate across payload, mechanical, power, and systems teams to ensure thermal constraints are integrated.
• Mentor junior engineers and contribute to best practices in thermal engineering.

Skills

Thermal design

Thermal analysis

Thermal modeling

Space hardware qualification

Cross-disciplinary collaboration

Strong communication

Education

Bachelor's degree in mechanical engineering, aerospace engineering, physics, or related field

Master's or PhD (preferred)

Tools

Thermal Desktop

SINDA/FLUINT

ANSYS Icepak

Job description

## Senior Thermal Engineer – ConstellationsApply: Reston, VA: Space Coast, FL: Huntsville, AL: Denver, CO: Greater Seattle Area: Full time: Posted Today: R72192Application close date: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! 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 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:CA applicants is $156,802.00 - $219,522.45CO applicants is $144,179.00 - $201,849.90WA applicants is $156,802.00 - $219,522.45VA applicants is $156,802.00 - $219,522.45