Senior Thermal Engineer – Payload Systems

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! Blue Origin is pioneering the future of space-based communications with TeraWave, a revolutionary satellite communications network designed to deliver symmetrical data speeds of up to 6 Tbps anywhere on Earth. This multi-orbit constellation will consist of optically interconnected satellites in low Earth orbit (LEO) and medium Earth orbit (MEO), providing enterprise-grade connectivity for critical operations worldwide. We are seeking a Senior Thermal Engineer to lead the thermal design and analysis of advanced phased array antenna systems for both satellite payloads and ground-based user terminals. This role is central to ensuring reliable performance of high-power, high-frequency antenna systems operating across harsh orbital and terrestrial environments, including Q/V-band and beyond. The ideal candidate brings deep expertise in thermal management of RF electronics, active phased arrays, and space-qualified hardware, along with the ability to drive cross-disciplinary design integration across mechanical, RF, digital, and power subsystems. This role offers the opportunity to shape next-generation satellite communication systems and high-performance ground terminals, enabling robust, high-capacity connectivity in increasingly demanding RF environments. Key Responsibilities: Lead thermal architecture development for satellite-based phased array antennas, including active RF front ends, beamforming ICs, and associated power electronics. Design and optimize thermal solutions for ground-based phased array terminals operating under dynamic environmental conditions (solar loading, ambient extremes, precipitation, and installation variability). Develop detailed thermal models using tools such as Thermal Desktop, SINDA/FLUINT, or equivalent, covering conduction, radiation, and convection regimes as appropriate. Define and manage thermal interfaces across payload subsystems, including radiators, heat pipes, loop heat pipes, cold plates, and structural elements. Perform transient and steady-state thermal analyses to validate performance under mission profiles, including peak RF duty cycles, eclipse transitions, and worst-case environmental conditions. Collaborate closely with RF, mechanical, and systems engineering teams to ensure thermal constraints are integrated into antenna element layout, T/R module design, and packaging. Establish thermal requirements, margins, and verification plans aligned with mission reliability and lifetime goals. Support hardware development, including thermal testing, correlation of models to test data, and anomaly resolution. Drive thermal design trades balancing performance, mass, power consumption, manufacturability, and cost for both space and ground systems. Mentor junior engineers and contribute to organizational best practices in thermal engineering. Required Qualifications: Bachelor’s degree in mechanical engineering, aerospace engineering, Physics or related field. 8+ years of experience in thermal engineering for aerospace, RF systems, or high-performance electronics. Demonstrated experience with spaceborne thermal design, including vacuum environments, radiation heat transfer, and flight hardware qualification. Strong understanding of phased array antenna systems, including thermal challenges associated with dense T/R module integration and high-power densities. Experience with thermal modeling tools (e.g., Thermal Desktop, SINDA/FLUINT, ANSYS Icepak, or equivalent). Knowledge of materials, coatings, and thermal interface technologies suitable for space and outdoor ground systems. Familiarity with environmental standards (e.g., NASA, ESA, MIL-STD) and qualification testing. Preferred Qualifications: Master’s or PhD degree in mechanical engineering, aerospace engineering, Physics or related field Experience with Q/V-band or higher frequency RF systems and associated thermal constraints. Background in both space and terrestrial antenna systems, particularly electronically steered arrays. Experience with advanced cooling techniques, including loop heat pipes, vapor chambers, and liquid cooling systems. Experience supporting production scaling and cost optimization for phased array hardware. Key Attributes: Strong systems thinking and ability to work across multidisciplinary teams. Ability to translate complex thermal challenges into practical engineering solutions. Proven leadership in driving designs from concept through qualification and deployment. Excellent communication skills for both technical and programmatic stakeholders. Compensation Range for: WA 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 (CDL drivers only), 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. 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