Space-Grade Encapsulation Process Lead

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

Benefits offered by this job

Medical

Dental

Vision

401(k) with company match

Education Support Program

Stock options

Paid time off

Job summary

Blue Origin seeks an expert to own the encapsulation process development pipeline from lamination through QA for solar/module packaging in space-grade contexts. You will bridge packaging design intent with fabrication realities, driving repeatable, hermetic encapsulation for high-reliability devices.

You will develop process parameters, materials qualification, and inline monitoring while coordinating with cross-functional teams to scale from coupons to full modules and ensure compatibility with

Qualifications

• B.Sc. in Chemical Eng., Materials Sci., Mechanical Eng. or related field.
• 5+ years encapsulation, lamination, or packaging process development for PV, OLED, or flexible electronics.
• Demonstrated experience developing lamination or sealing processes.
• Strong understanding of polymer processing: glass transition, crosslinking, adhesion, aging mechanisms.
• Experience with accelerated aging test design and lifetime prediction methodologies.
• Proficiency with process characterization tools: DSC, TGA, DMA, peel testing, optical microscopy, moisture sensors.
• Track record of transferring encapsulation processes from development to production-representative scale.

Responsibilities

• Develop lamination processes for encapsulation: temperature profiles, pressure schedules, atmosphere control, and cure protocols.
• Qualify encapsulant materials for compatibility with device stack.
• Develop and validate thin-film encapsulation processes (PECVD, ALD-based barriers).
• Design accelerated aging studies for space environments and launch path.
• Optimize edge-sealing processes for hermeticity and reliability.
• Establish inline process monitoring and acceptance criteria for encapsulation steps.
• Perform failure analysis on degraded modules.
• Develop process documentation, SPC charts, and process capability studies.

Skills

Encapsulation process development

Lamination & sealing processes

Aging & lifetime prediction

Process characterization tools

Production transfer of encapsulation

Education

B.Sc. Chemical Engineering / Materials Science / Mechanical Engineering (or related)

Tools

DSC

TGA

DMA

Peel testing

Optical microscopy

Moisture sensors

Job description

Blue Origin seeks an expert to own the encapsulation process development pipeline from lamination through QA for solar/module packaging in space-grade contexts. You will bridge packaging design intent with fabrication realities, driving repeatable, hermetic encapsulation for high-reliability devices.

You will develop process parameters, materials qualification, and inline monitoring while coordinating with cross-functional teams to scale from coupons to full modules and ensure compatibility with