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Staff Mechanical Engineer, Spacecraft Engineer
5 hours ago
We are seeking a Staff Mechanical Engineer to lead the mechanical design and manufacturability of next-generation Hall-effect thrusters for spacecraft propulsion. This position is critical in ensuring propulsion systems achieve world-class performance and reliability in orbit, while also being optimized for repeatable, cost-effective, and scalable production.
The ideal candidate combines deep expertise in mechanical design for extreme environments with a proven ability to apply design-for-manufacture (DFM) and design-for-assembly (DFA) principles. This is a leadership role with direct impact on the design, integration, and qualification of propulsion hardware that must survive launch and operate reliably for years in space.
Key Responsibilities
- Own the mechanical architecture of Hall-effect thrusters, including discharge channels, magnetic circuits, and electrode assemblies
- Drive DFM/DFA practices to scale hardware from prototypes into high-volume production
- Specify advanced materials, coatings, and joining methods suitable for plasma environments and long-duration missions
- Perform structural, thermal, and dynamic analyses to validate designs against launch and space environments
- Collaborate with suppliers and manufacturing teams to resolve producibility challenges and qualify vendors
- Lead and support mechanical testing campaigns (vibration, shock, thermal-vacuum, life testing) for flight hardware
- Partner with plasma physics, electrical, and systems engineering teams to ensure integrated thruster performance
- Mentor engineers, review designs, and serve as subject matter expert in manufacturable spacecraft propulsion hardware
- Champion continuous improvement to simplify, standardize, and modularize designs for reduced cost and faster production cycles
Compensation
- Base salary range: $150,000 - $185,000 per year (Bay Area market range; excludes bonuses and benefits)
Minimum Qualifications
- Bachelor's or Master's degree in Mechanical, Aerospace, or related engineering field
- 5+ years of experience in mechanical design of aerospace hardware (propulsion or high-reliability spacecraft systems)
- Expertise in structural, thermal, and materials design considerations for spaceflight hardware
- Proven track record applying DFM/DFA principles to aerospace hardware transitioned into production
- Proficiency with CAD and analysis tools (SolidWorks, Creo, NX, ANSYS, or equivalent)
- Hands-on experience with qualification testing (vibration, shock, thermal-vacuum)
- Familiarity with aerospace standards (NASA, ESA, ECSS, MIL-STD, or equivalent)
- Strong communication and leadership skills with ability to mentor teams and influence system-level decisions
Preferred Skills / Multipliers
- Direct experience with electric propulsion hardware (Hall-effect thrusters, ion engines)
- Knowledge of high-temperature materials, ceramics, or coatings for plasma-facing components
- Experience scaling hardware from development units to flight production
- Familiarity with additive manufacturing or advanced manufacturing techniques for propulsion
- Previous leadership as a mechanical lead or system architect for flight-qualified hardware
Other Requirements
- Must meet ITAR/EAR compliance as a U.S. Person (citizen, permanent resident, refugee, or asylee) or be eligible for licensing
- Subject to background checks and, if applicable, government contract clearance
- Applicants in San Francisco will be considered consistent with the Fair Chance Ordinance
