Sr. Senior Manufacturing Surface Treatment, Sealing & Adhesion DFX Engineer

Blue Origin; San Francisco (CA); On-site; USD 157,000 - 220,000; Full time

Benefits offered by this job

Relocation assistance

Stock options

Medical, dental, vision

Paid time off

Parental leave

Job summary

Blue Origin in San Francisco is seeking a Sr. Senior Manufacturing Surface Treatment, Sealing & Adhesion DFX Engineer to own end-to-end surface treatment, sealing and adhesion design for TeraWave modules, bridging coatings, bonding, sealing and volume production readiness for orbital-scale hardware.

This hands-on role requires developing and qualifying surface prep, adhesive and coating procedures, managing materials BOMs, and guiding first-article inspection, process validation and

Qualifications

• Bachelor's degree in Materials Science, Chemical Engineering, Mechanical Engineering, or related field.
• 10+ years of surface treatment, adhesive bonding, sealing, or coatings process engineering in product development and volume production.
• Experience developing and qualifying surface prep, bonding, sealing, and coating processes with tight performance and reliability requirements.
• Hands-on experience with adhesive/coating application, cure development, surface analysis, tooling/fixturing, and line bring-up.
• Demonstrated application of DFX principles (DFM/DFT/DFA/DFR) in bringing surface treatment, sealing, or adhesion to volume production.
• Excellent technical documentation and communication skills.

Responsibilities

• Lead surface treatment, sealing, and adhesion process design for satellite modules and subsystems: conformal coatings, surface prep, anodizing/plating, bonding, potting, sealing.
• Own process development from preparation through cure and integration workflows to ensure repeatable results.
• Manage materials BOM procurement, vendor coordination, process qualification, and assembly oversight.
• Drive first-article inspection, bond/coating verification, process validation, and manufacturing readiness reviews for ramp.

Skills

Surface treatment

Adhesive bonding

Sealing

Coatings

DFX principles

Process engineering

DFM

DFT

DFR

Education

Bachelor's degree in relevant field

Tools

SEM

Contact angle

Adhesion testing

Job description

Sr. Senior Manufacturing Surface Treatment, Sealing & Adhesion DFX Engineer

life insurance, parental leave, paid time off, paid holidays, 401(k), stock options, relocation assistance

Sep 12, 2026

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 Surface Treatment, Sealing & Adhesion DFX Engineer, you will own the end-to-end surface treatment, sealing, and adhesion process design integration of TeraWave modules - bridging coatings, bonding, sealing, 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 developed, qualified, and shipped complex surface treatment, bonding, and sealing processes 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: Surface Treatment, Sealing & Adhesion Process Design, Integration & Manufacturing

• Lead surface treatment, sealing, and adhesion process design for satellite modules and subsystems: conformal coatings, surface preparation, anodizing/plating, structural and thermal bonding, potting, staking, and hermetic/environmental sealing.
• Own process development - including surface prep procedures, adhesive and coating selection, cure profiles, application tooling, and integration workflows - to ensure robust, repeatable results.
• Manage materials and consumables BOM procurement, vendor coordination, process qualification, and assembly oversight.
• Drive first-article inspection, bond/coating verification, process validation, and manufacturing readiness reviews to support production ramp.

Design for Excellence (DFX)

• Drive Design for Excellence (DFX) principles - DFM, DFT, DFA, DFR, and DFS - across the full surface treatment, sealing, and adhesion lifecycle to ensure hardware scales from prototype through volume production for TeraWave operations.
• Design for Manufacturability (DFM): Optimize surface preparation, coating and adhesive selection, joint geometry, and application processes to maximize yield and minimize cost at constellation‑scale production volumes.
• Design for Test (DFT): Integrate inspection features, bond/coating verification methods, and process monitoring to enable efficient factory acceptance and in‑field diagnostics.
• Design for Assembly (DFA): Simplify surface prep, application, masking, and cure steps to reduce process time, rework, and error rates on the line.
• Design for Reliability (DFR): Apply material compatibility analysis, outgassing (ASTM E595) considerations, FMEA, thermal‑mechanical and adhesion strength analysis, and reliability prediction to ensure long‑duration bond and seal integrity in the orbital environment.
• Design for Serviceability/Supply Chain (DFS): Coordinate with supply chain and manufacturing partners to drive material standardization, second‑sourcing strategies, shelf‑life management, and obsolescence mitigation across the production lifecycle.
• Partner with manufacturing, quality, and supply chain teams to define acceptance criteria, drive yield optimization, and support production ramp for sustained TeraWave operations.

Minimum Qualifications:

• Bachelor's degree in Materials Science, Chemical Engineering, Mechanical Engineering, or a related field.
• 10+ years of experience in surface treatment, adhesive bonding, sealing, or coatings process engineering in a product development and volume production environment.
• Experience developing and qualifying surface preparation, bonding, sealing, and coating processes with tight performance and reliability requirements.
• Hands‑on experience with adhesive/coating application processes, cure development, surface analysis, tooling and fixturing, and line bring‑up.
• Demonstrated application of DFX principles (DFM/DFT/DFA/DFR) in bringing surface treatment, sealing, or adhesion processes from design into volume production.
• Excellent technical documentation and communication skills.

Preferred Qualifications:

• Master's degree in Materials Science, Chemical, or Mechanical Engineering.
• 15+ years of relevant experience.
• Experience with space‑grade materials, low‑outgassing adhesives/coatings (ASTM E595), and material compatibility for vacuum environments.
• Experience with surface analysis techniques (SEM, contact angle, adhesion testing) and process characterization.
• Experience developing and qualifying processes for space, aviation, or other high‑reliability thermal‑vacuum environments.
• Experience with bond strength, thermal, or environmental durability analysis in a design context.
• Background in production hardware including comprehensive DFX practices (DFM/DFT/DFA/DFR), process optimization, supply chain coordination, and yield optimization at scale.
• Hands‑on environmental qualification testing (TVAC, vibration, EMI/EMC, thermal cycling).

Why Blue Origin

At Blue Origin, we are driven by Gradatim Ferociter - "Step by Step, Ferociously." As a Senior Manufacturing Surface Treatment, Sealing & Adhesion DFX Engineer, you will design and industrialize the material and bonding processes protecting an orbital constellation at unprecedented scale, alongside world‑class engineers solving problems at the intersection of advanced manufacturing, materials science, and spaceflight.

Base Pay Range for:

CA applicants is $156,802.00 - $219,522.45

Other site ranges may differ

Culture Statement

Don't meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you're excited about this role but your past experience doesn't align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.

Export Control Regulations

Applicants for employment at Blue Origin must be a U.S. citizen or national, U.S. permanent resident (i.e. current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Background Check

• Required for all positions: Blue's Standard Background Check
• Required for Certain Job Profiles: Defense Biometric Identification System (DBIDS) background check if at any time the role requires one to be on a military installation
• Required for Certain Job Profiles: Drivers who operate Commercial Motor Vehicles with a Gross Vehicle Weight (GVW), Gross Vehicle Weight Rating (GVWR) or combination of power unit and trailer that meets or exceeds 10,001 lbs. and/or transports placardable amounts of hazardous materials by ground in any vehicle on a public road while in commerce, may be subject to additional Federal Motor Carrier Safety Regulations including: Driver Qualification Files, Medical Certification (obtained before onboarding), Road Test, Hours of Service, Drug and Alcohol Testing, vehicle inspection requirements, CDL requirements (if applicable) and hazardous materials transportation/shipping training.
• Required for certain Job Profiles: Ability to obtain and maintain Merchant Mariner Credential, which includes pre-employment and random drug testing as well as DOT physical

Benefits

• Benefits include: Medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability, 401(k) with a company match of up to 5%, and an Education Support Program.
• Stock Options for all regular employees (working at least 20 hours/week)
• Paid Time Off: Up to four (4) weeks per year based on weekly scheduled hours, and up to 14 company-paid holidays.
• Dependent on role type and job level, employees may be eligible for benefits and bonuses based on the company's intent to reward individual contributions and enable them to share in the company's results, or other factors at the company's sole discretion. Bonus amounts and eligibility are not guaranteed and subject to change and cancellation. Please check with your recruiter for more details.

Equal Employment Opportunity

Blue Origin is proud to be an Equal Opportunity/Affirmative Action Employer and is committed to attracting, retaining, and developing a highly qualified and dedicated work force. Blue Origin hires and promotes people on the basis of their qualifications, performance, and abilities. We support the establishment and maintenance of a workplace that fosters trust, equality, and teamwork. We provide all qualified applicants for employment and employees with equal opportunities for hire, promotion, and other terms and conditions of employment, regardless of their race, color, religion, sex, sexual orientation, gender identity, national origin/ethnicity, age, physical or mental disability, genetic factors, military/veteran status, or any other status or characteristic protected by federal, state, and/or local law. Blue Origin will consider for employment qualified applicants with criminal histories in a manner consistent with applicable federal, state, and local laws, including the Washington Fair Chance Act, the California Fair Chance Act, the Los Angeles Fair Chance in Hiring Ordinance, and other applicable laws. For more information on "Know Your Rights," please see here.

Affirmative Action and Disability Accommodation

Applicants wishing to receive information on Blue Origin's Affiant ... contact us [e-mail]. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.

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