Sr. Manufacturing Mechanical Assembly DFX Engineer

Blue Origin LLC; California (MO); Hybrid; USD 122,000 - 203,000; Full time

Benefits offered by this job

Relocation assistance

Travel up to 50%

Job summary

Blue Origin LLC in the Bay Area, CA is seeking a Senior Manufacturing Mechanical Assembly DFX Engineer to own the end-to-end mechanical assembly design integration for TeraWave modules, bridging structural design, mechanical integration, and production readiness.

This role requires hands-on experience in fast-moving, high-volume manufacturing environments and travel up to 50%. It offers relocation assistance and supports contributing to constellation-scale hardware manufacturing.

Qualifications

• Bachelor's degree in Mechanical/Manufacturing Engineering required.
• 10+ years of mechanical design/manufacturing engineering experience.
• Proficiency in 3D CAD and GD&T per ASME Y14.5.
• US citizen or permanent resident for access to export-controlled data.
• Aerospace/defense or space launch manufacturing experience preferred.

Responsibilities

• Lead and facilitate DFX reviews (DFM, DFA, DFT, DFC) through product lifecycle.
• Provide manufacturing feedback early in the design cycle to improve producibility.
• Analyze drawings/models to identify manufacturability risks.
• Develop and maintain DFX guidelines and standards for various processes.
• Support NPIs and production readiness reviews.
• Mentor junior engineers on DFX principles.

Education

Bachelor's degree in Mechanical/Manufacturing Engineering

Master's degree in Mechanical/Manufacturing Engineering

Tools

NX

CATIA

SolidWorks

Job description

## Sr. Manufacturing Mechanical Assembly DFX EngineerApply: Bay Area, CA: Full time: Posted Today: R71989Application 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! This role is part of Blue Origin Operations, which is comprised of Integrated Supply Chain, Test Operations, Safety, Quality, and Mission Assurance. This includes Manufacturing and Supply Chain support across all Blue Origin facilities.Blue Origin's Emerging Systems business unit is building TeraWave, a satellite communications constellation powered by the most advanced optical communications architecture ever attempted: thousands of optically interconnected satellites delivering symmetrical data speeds of up to 6 Tbps anywhere on Earth, providing enterprise and hyperscale customers with resilient, scalable connectivity for critical operations where terrestrial infrastructure cannot reach.As a Senior Manufacturing Mechanical Assembly DFX Engineer, you will own the end-to-end mechanical assembly design integration of TeraWave modules — bridging structural design, mechanical integration, and volume production readiness. As a foundational element of TeraWave operations, hardware must be architected not only for performance but for manufacturability, testability, reliability, and serviceability at constellation scale. This is a hands-on role for an engineer who has designed, integrated, and shipped complex mechanical assemblies in fast-moving, high-volume manufacturing environments and wants to apply that experience to hardware operating at orbital scale.**Special Mentions:*** Relocation assistance is available for qualified candidates.* Travel: Up to 50%.**Responsibilities*** Lead and facilitate **DFX reviews** (DFM, DFA, DFT, DFC) throughout all phases of the product lifecycle, from concept through production* Partner with design engineering teams to provide **manufacturing feedback early in the design cycle**, identifying risks and opportunities to improve producibility* Analyze complex mechanical drawings, models (CAD), and assemblies to identify **design features that may be difficult, costly, or risky to manufacture*** Develop and maintain **DFX guidelines, best practices, and standards** for machined parts, sheet metal, composites, castings, forgings, welded structures, and other manufacturing processes* Drive design trade studies and cost-benefit analyses to support **design optimization decisions*** Collaborate with suppliers and internal manufacturing teams to understand **process capabilities and constraints*** Support **cost reduction and producibility improvement initiatives** on existing hardware* Engage with quality engineering to identify and resolve **design-driven quality issues*** Contribute to the development and review of **GD&T (Geometric Dimensioning and Tolerancing)** and tolerance stack-up analyses* Support **NPI (New Product Introduction)** and production readiness reviews* Provide technical input to **make vs. buy decisions** and manufacturing process selection* Mentor junior engineers on DFX principles and manufacturing best practices**Minimum Qualifications*** Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or related technical discipline* 10+ years of experience in mechanical design, manufacturing engineering, or a closely related field* Strong working knowledge of **DFM/DFA/DFX methodologies*** Proficiency in **3D CAD tools** (NX, CATIA, SolidWorks, or equivalent)* Experience reading and interpreting **engineering drawings and GD&T** per ASME Y14.5* Familiarity with a broad range of manufacturing processes, including: + CNC machining + Sheet metal fabrication + Welding and joining + Composite manufacturing + Casting and forging + Additive manufacturing* Excellent communication skills with the ability to clearly convey technical concepts to cross-functional teams* Must be a U.S. citizen or permanent resident (required for access to export-controlled data)**Preferred Qualifications*** Master's degree in Mechanical or Manufacturing Engineering* Experience in **aerospace, defense, or space launch vehicle** manufacturing environments* Familiarity with **AS9100** quality management systems* Experience with **tolerance stack-up analysis tools** (e.g., 3DCS, VSA)* Knowledge of **lean manufacturing** and continuous improvement methodologies (Six Sigma, Kaizen)* Experience with **Model-Based Definition (MBD)** and paperless manufacturing environments* Hands-on experience in a **production or shop floor environment*** Background in **cost modeling** or should-cost analysis## Why Blue OriginAt Blue Origin, we are driven by Gradatim Ferociter — \"Step by Step, Ferociously.\" As a Senior Manufacturing Mechanical Assembly DFX Engineer, you will design and industrialize the foundational hardware connecting an orbital constellation at unprecedented scale, alongside world-class engineers solving problems at the intersection of advanced manufacturing, mechanical design, and spaceflight.### Base Pay Range for:CA applicants is $145,188.00 - $203,263.20