Sr. Senior Manufacturing Surface Treatment, Sealing & Adhesion 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 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 st