Sr. Manufacturing Mechanical Assembly DFX Engineer

Blue Origin LLC; Cupertino (CA); On-site; USD 150,000 - 210,000; Full time

Job summary

Blue Origin LLC is seeking a Senior Manufacturing Mechanical Assembly DFX Engineer to own the end-to-end mechanical assembly design integration of TeraWave modules — bridging structural design, mechanical integration, and volume production readiness.

This role emphasizes hardware design for manufacturability, testability, reliability, and serviceability at constellation scale, requiring hands-on experience in fast-moving, high-volume environments operating in orbital-scale contexts.

Qualifications

• Bachelor's degree in Mechanical/Manufacturing Engineering or related field.
• 10+ years of mechanical design/manufacturing engineering experience.
• Strong knowledge of DFM, DFA, DFX.
• Proficient in 3D CAD tools: NX, CATIA, SolidWorks or equivalent.
• Experience reading engineering drawings and GD&T per ASME Y14.5.
• U.S. citizen or permanent resident for export-controlled data access.

Responsibilities

• Lead and facilitate DFX reviews throughout the product lifecycle, from concept through production.
• Provide manufacturing feedback early in the design cycle, identifying risks and opportunities to improve producibility.
• Analyze complex mechanical drawings, models, and assemblies to identify design features that may be difficult or costly to manufacture.
• Develop and maintain DFX guidelines, best practices, and standards for machined parts, sheet metal, composites, castings, forgings, welded structures.
• 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 and tolerance stack-up analyses.
• Support NPI and production readiness reviews.
• Provide input to make vs. buy decisions and manufacturing process selection.
• Mentor junior engineers on DFX principles and manufacturing best practices.

Skills

DFM/DFA/DFX methodologies

CAD Proficiency

GD&T

Manufacturing Eng

Communication

Education

Bachelor's degree in Mechanical/Manufacturing Engineering

Tools

NX

CATIA

SolidWorks

Job description

Application 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)