Sr. Manufacturing RF DFX Engineer at Blue Origin in Bay Area, CA

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 RF DFX Engineer, you will own the end-to-end RF assembly design integration of TeraWave modules — bridging RF/microwave circuit design, antenna and feed 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 RF 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: RF Assembly Design, Integration & Manufacturing Lead RF/microwave assembly design for satellite communication modules and subsystems: RF front-ends, transceivers, filters, amplifiers, antenna feeds, waveguides, and mechanical integration of RF hardware. Own RF assembly process development — including impedance-controlled routing, shielding, connectorization, calibration procedures, and integration workflows — to ensure robust, repeatable assembly. Manage RF BOM procurement, vendor coordination, RF performance and tolerance analysis, and assembly oversight. Drive first-article inspection, RF performance validation, 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 RF assembly lifecycle to ensure hardware scales from prototype through volume production for TeraWave operations. Design for Manufacturability (DFM): Optimize RF board stackups, transmission line geometry, material selection, shielding, and assembly processes to maximize yield and minimize cost at constellation-scale production volumes. Design for Test (DFT): Architect RF test structures, calibration references, test points, and automated RF test coverage to enable efficient factory acceptance and in-field diagnostics. Design for Assembly (DFA): Simplify connector selection, shielding integration, component placement, and mechanical integration to reduce assembly time, rework, and error rates on the line. Design for Reliability (DFR): Apply derating, worst-case circuit analysis, FMEA, thermal-mechanical and vibration analysis, and reliability prediction to ensure stable RF performance and long-duration operation in the orbital environment. Design for Serviceability/Supply Chain (DFS): Coordinate with supply chain and manufacturing partners to drive component standardization, second-sourcing strategies, and obsolescence mitigation across the production lifecycle. Partner with manufacturing, quality, and supply chain teams to define acceptance cr