TCA Mechanical Design Engineer Level 1

Cowboy Space Corp.; Kent (WA); On-site; USD 100,000 - 150,000; Full time

Benefits offered by this job

Equity

Insurance

401(k) retirement plan

Paid time off

10 paid holidays per year

Paid parental leave

Relocation assistance

Lunch provided

Job summary

Cowboy Space Corp. in Kent, WA is seeking a TCA Mechanical Design Engineer Level 1 to own hardware design for rocket injector, chamber, and nozzle development, with hands-on shop and lab experience.

You will work with propulsion, structures, thermal, materials, manufacturing, and test ops, progressing designs through rapid build/test cycles under senior engineers.

This onsite role offers ownership from day one, equity, comprehensive benefits, and opportunities in a fast-moving space startup.

Qualifications

• Bachelor's degree in Mechanical, Aerospace, or Manufacturing Engineering.
• 1+ years of mechanical design experience for rocket/hardware; internships/co-ops count.
• DFM/DFMA emphasis leads to fabrication/assembly experience.
• Proficiency with 3D CAD and ASME Y14.5 GD&T standards.

Responsibilities

• Own end-to-end TCA hardware lifecycle from requirements to flight qualification.
• Lead mechanical design optimized for manufacturability with physics-based analysis.
• Implement additive manufacturing, precision CNC, EDM, and specialized joining.
• Design tooling, fixtures, and work-holding for rapid development and repeatable production.
• Develop and qualify manufacturing process parameters for novel materials/geometries.
• Plan and execute hotfire test campaigns and lead rapid redesigns.
• Release production-ready models, drawings, specifications, and release documentation.
• Collaborate with machinists, welders, and technicians on the shop floor.

Skills

DFM/DFMA

3D CAD

FEA

Thermo/Fluid

Shop floor

Collaboration

Education

Bachelor's degree in Mechanical/Aerospace/Manufacturing Engineering

Tools

NX

SolidWorks

CATIA

Creo

ANSYS/Fluent/Thermal Desktop

Job description

TCA Mechanical Design Engineer Level 1

Cowboy Space Corp. is building the infrastructure to power and connect the orbital economy. Our satellites operate in Low Earth Orbit to collect sunlight and enable a new class of capabilities-from powering on-orbit compute, to transmitting energy via infrared lasers (space-to-earth and space-to-space), to delivering secure, high-bandwidth optical data. By rethinking how energy and data are generated and distributed in space, we’re unlocking entirely new ways to operate both in orbit and on Earth.

Founded in 2024 by Baiju Bhatt (co-founder of Robinhood), Cowboy Space Corp. is backed by leading investors and built by a team from top aerospace and defense organizations. We’re moving quickly to solve complex technical challenges and build a new category of space infrastructure.

About the Role

We are seeking a TCA Mechanical Design Engineer Level 1 who is eager to build depth in manufacturing processes, tooling design, and specialized fabrication methodologies for rocket engine injector, combustion chamber, and nozzle development. The ideal candidate pairs a strong mechanical engineering foundation with hands-on shop and lab experience from internships, co-ops, or student design-build-test teams. This is a real ownership role from day one: you will own TCA hardware through rapid design/build/test cycles, with senior TCA engineers to learn from. You will work closely with propulsion, structures, thermal, materials and processes, manufacturing, and test operations. This position is located onsite in Kent, WA.

Responsibilities

• Own end-to-end TCA hardware lifecycle from requirements through manufacturing to flight qualification
• Lead mechanical design optimized for manufacturability, applying physics-based analysis - hand calculations, thermal and structural FEA, and tolerance stack-ups
• Implement advanced manufacturing techniques: additive manufacturing, precision CNC machining, EDM, and specialized joining (e.g. laser welding, vacuum brazing, diffusion bonding)
• Design tooling, fixtures, and work-holding solutions for rapid development and repeatable production
• Develop and qualify manufacturing process parameters for novel materials and geometries
• Plan and execute hotfire test campaigns, analyze results, and lead rapid redesign efforts balancing performance with manufacturing constraints
• Release production-ready models, drawings, specifications, and release documentation
• Work directly with machinists, welders, and technicians on the shop floor to close the loop between design intent and what actually gets built

Basic Qualifications

• Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering
• 1+ years of experience in mechanical design for rocket engine or comparable high-performance hardware. Internships, co-ops, and competition or research team experience count.
• Strong mechanical design proficiency with DFM/DFA emphasis, leading to hands-on fabrication, assembly or component manufacturing experience
• Proficiency with 3D CAD (NX, SolidWorks, CATIA, or Creo), structural analysis tools, and creating engineering drawings to ASME Y14.5 GD&T standards
• Strong fundamentals in thermodynamics, fluid dynamics, and structural mechanics
• Must be a U.S. citizen or national, lawful permanent resident, protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State

Preferred Qualifications

• 2+ years of experience with rocket engine TCA hardware, including component lifecycle ownership through production
• Hands-on experience with CNC machining, welding/brazing, or additive manufacturing
• Design for Additive Manufacturing (DfAM) experience
• Precision machining knowledge: 5-axis CNC, high-speed machining, Swiss machining
• Specialized joining expertise: vacuum brazing, electron beam/laser welding, friction stir welding
• Tooling design: fixtures, EDM electrodes, CMM/welding fixtures
• Ansys Mechanical, Fluent, or Thermal Desktop experience
• Master's degree in an engineering discipline
• Leadership role on a student rocketry, Formula SAE, or similar design-build-test team
• Willingness to spend regular time on the shop floor and at the test stand, including occasional off-hours work during test campaigns
• Experience at a fast-moving, hardware-focused startup or early-stage program

Compensation and Benefits

The salary range for this position is $100,000 - $150,000 annually. The actual base salary offered will depend on factors such as job-related skills, experience, qualifications, and internal equity.

• Equity in Cowboy Space Corp.
• Employees and their eligible dependents may enroll in medical, dental, and vision insurance
• 401(k) retirement savings plan
• Paid time off
• 10 paid holidays per calendar year
• Paid parental leave
• Relocation assistance if applicable
• Daily lunch in the office and a fully stocked kitchen with beverages and snacks

ITAR Requirements

• Export Control Requirement: To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), applicants must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Learn more about ITAR here.

Disclaimer

This job description is a summary of the primary duties and responsibilities of the job and position. It is not intended to be a comprehensive or all-inclusive listing of duties and responsibilities. Contents are subject to change at Cowboy Space Corp.'s discretion.

Equal Employment Opportunity Statement

Cowboy Space Corp. is an equal employment opportunity employer. We consider individuals for employment or promotion according to their skills, abilities and experience. Cowboy Space Corp. is committed to complying with all applicable laws prohibiting discrimination based on race, color, religious creed, age, national origin, ancestry, physical, mental or developmental disability, sex (which includes pregnancy, childbirth, breastfeeding and medical conditions relating to pregnancy, childbirth or breastfeeding), veteran status, military status, marital or registered domestic partnership status, medical condition (including cancer or genetic characteristics), genetic information, gender, gender identity, gender expression, sexual orientation, as well as any other category protected by federal, state or local laws.