Senior Thermal Engineer - TeraWave

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 own thermal architecture and design for our TeraWave satellite user terminal — a compact, outdoor-deployed device that must dissipate significant heat from high-power beamforming electronics while operating reliably across extreme environmental conditions and remaining sealed against weather intrusion. This role is critical to product reliability and performance: the terminal must sustain full RF/digital performance under direct sunlight, high ambient temperatures, and enclosed/sealed conditions (IP67+) — without active cooling in most consumer deployment scenarios. You will drive thermal simulation, material selection, and physical design solutions from concept through mass production, working closely with RF, Electrical, PCB, and Mechanical engineering teams. Core Responsibilities include but are not limited to Define the overall thermal management strategy for the user terminal, balancing passive cooling requirements against cost, weight, and form-factor constraints typical of consumer/enterprise hardware. Build and maintain detailed thermal models (CFD and FEA) of the full system — PCB, enclosure, beamforming ICs, power electronics — to predict junction temperatures, hot spots, and derating requirements under worst-case operating conditions. Work with RF and EE teams to build system-level power dissipation budgets, identifying high-heat-flux components (BFICs, power amplifiers, PMICs, processors) early in the design cycle. Design and specify heat spreading and dissipation solutions — heat sinks, heat pipes, vapor chambers, thermal interface materials (TIMs), and PCB thermal via/copper strategies — in collaboration with PCB and mechanical teams. Solve the specific challenge of passive heat rejection from a sealed (IP67+) outdoor enclosure without compromising weatherproofing, including consideration of convection, radiation, and conduction paths to the external environment. Ensure thermal designs meet operational requirements across full environmental spec (e.g., -40°C to +65°C ambient, solar loading, altitude, humidity) and support environmental qualification testing (HALT/HASS, thermal cycling, thermal shock). Select and validate thermal interface materials, gap fillers, thermal adhesives, and enclosure materials (metals, thermally conductive plastics) for performance, cost, and manufacturability. Lead thermal characterization testing on prototype hardware — thermal imaging, thermocouple instrumentation, chamber testing — to validate simulation models and identify design gaps. Ensure thermal solutions (heat sinks, TIMs, potting, gap pads) are compatible with high-volume manufacturing and assembly processes; work with CM partners on thermal solution assembly. Partner with RF engineers to understand thermal derating impacts on BFIC/PA performance, and with mechanical/industrial design to co-develop enclosure geometry that supports passive heat rejection. Produce thermal analysis reports, design guidelines, and derating curves to inform component selection and system-level design decisions across the hardware team. Required Qualifications Bachelor's or Master's degree in Mechanical Engineering , Aerospace Engineering, or related field with a focus on heat transfer/thermal sciences. 7+ years of thermal engineering experience in electronics hardware, with direct experience on high-power-density, densely packed consumer or telecom hardware (RF systems, base stations, networking equipment, or similar). Proficiency in industry-standard thermal simulation tools (e.g., Ansys Icepak , Siemens Simcenter FLOTHERM, 6SigmaET, or equivalent) for both component-level and system-level thermal modeling. Demonstrated experience designing passive thermal solutions (no fans/active cooling) for sealed or environmentally exposed electronics enclosures. Direct experience solving thermal challenges within IP-rated sealed enclosures, understanding tradeoffs between weatherproofing and heat rejection. Strong working knowledge of thermal interface materials (TIMs), gap fillers, thermally conductive potting/adhesives, and their tradeoffs (thermal conductivity, cost, reliability, assembly process). Hands-on experience with thermal characterization testing — thermal imaging cameras, thermocouples, environmental chambers, and correlating test data to simulation. Proven ability to work closely with electrical, RF, and mechanical engineering teams to translate power dissipation and component thermal limits into practical design solutions. Understanding of how PCB stack up , copper weight, and thermal via strategy contribute to overall system heat dissipation (ability to collaborate effectively with PCB design team). , logic analyzers, JTAG debuggers) to isolate hardware vs. software issues. Preferred Qualifications (Bonus Skills) Specific experience managing thermal design for RF power amplifiers, beamforming ICs, or similarly high-heat-flux RF components. Experience transitioning thermal solutions from prototype to mass production, with awareness of cost-down pressures and DFM/DFA for thermal hardware (heat sinks, TIMs, gap pads). Experience modeling and mitigating solar thermal loading for outdoor-deployed electronics . Familiarity with HALT/HASS methodology and thermal cycling/thermal shock testing as part of product qualification. Familiarity with relevant environmental and reliability standards (IEC 60068, MIL-STD-810, Telcordia GR-487) for outdoor telecom equipment. Experience co-designing enclosure geometry (fins, ribs, venting where applicable) with industrial design/mechanical teams to optimize passive heat rejection while maintaining product aesthetics and IP rating Base Pay 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, 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. Blue Origin will consider for employment qualified applicants with criminal histories in a manner consistent with applicable federal, state, and local laws, including the Washington Fair Chance Act, the California Fair Chance Act, the Los Angeles Fair Chance in Hiring Ordinance, and other applicable laws. For more information on “Know Your Rights,” please see here . Affirmative Action and Disability Accommodation Applicants wishing to receive information on Blue Origin’s Affirmative Action Plans, or applicants requiring a reasonable accommodation in order to participate in the application and/or interview process, please contact us at . Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.