Manufacturing Process Flow & Control DFX Engineer III (Subsystem) — TeraWave Operation

Application close date:

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'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 Process Flow & Control DFX Engineer (Subsystem), you will own the end-to-end manufacturing process flow and process control design integration at the subsystem level for TeraWave production - bridging subsystem-level production line architecture, process control systems, and volume production readiness. As a foundational element of TeraWave operations, subsystems must be produced through process flows architected not only for throughput but for manufacturability, testability, reliability, and serviceability at constellation scale. This is a hands-on role for an engineer who has designed, optimized, and scaled complex subsystem-level manufacturing process flows and control systems 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:

Subsystem Process Flow & Control Design, Integration & Manufacturing

• Lead subsystem-level manufacturing process flow design across satellite subsystems: subsystem production line architecture, inter-station workflow sequencing, subassembly integration points, takt time optimization, and material flow between subsystem builds.
• Own subsystem process control development - including statistical process control (SPC), process monitoring, traveler and work instruction systems, MES integration, and data collection workflows across subsystem boundaries - to ensure robust, repeatable production.
• Manage subsystem-level process documentation, routing definition, capacity planning, cross-subsystem coordination, and production line oversight.
• Drive subsystem process validation, control plan development, first-article and production 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 subsystem-level manufacturing process flow and control lifecycle to ensure hardware scales from prototype through volume production for TeraWave operations.
• Design for Manufacturability (DFM): Optimize subsystem process sequencing, station layout, and cross-subsystem workflow to maximize yield, throughput, and minimize cost at constellation-scale production volumes.
• Design for Test (DFT): Architect subsystem-level in-line test and inspection points, data capture, and process monitoring to enable efficient subassembly acceptance, traceability, and in-field diagnostics.
• Design for Assembly (DFA): Simplify subsystem process steps, minimize handoffs between subsystem builds, and optimize integration points to reduce cycle time, rework, and error rates.
• Design for Reliability (DFR): Apply process FMEA, control plans, statistical process control, and reliability prediction to ensure consistent, defect-free subsystem production supporting long-duration operation in the orbital environment.
• Design for Serviceability/Supply Chain (DFS): Coordinate with supply chain and manufacturing partners to align subsystem process flows with material availability, standardization, and obsolescence mitigation across the production lifecycle.
• Partner with manufacturing, quality, and supply chain teams to define subsystem acceptance criteria, drive yield and throughput optimization, and support production ramp for sustained TeraWave operations.

Minimum Qualifications:

• Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or a related field.
• 10+ years of experience in manufacturing process engineering, process flow design, or production control in a product development and volume production environment.
• Experience designing and optimizing subsystem-level manufacturing process flows, line balancing, and process control systems for complex hardware.
• Hands-on experience with statistical process control (SPC), process FMEA, control plans, MES/ERP systems, and production line bring-up.
• Demonstrated application of DFX principles (DFM/DFT/DFA/DFR) in bringing subsystem process flows from design into volume production.
• Excellent technical documentation and communication skills.

Preferred Qualifications:

• Master's degree in Industrial, Manufacturing, or Mechanical Engineering.
• 15+ years of relevant experience.
• Lean Six Sigma certification (Green Belt or Black Belt) or equivalent process improvement expertise.
• Experience with high-mix or high-volume subsystem production line design, automation integration, and Industry 4.0 / smart factory concepts.
• Experience developing subsystem process flows for space, aviation, or other high-reliability manufacturing environments.
• Experience with capacity modeling, simulation, and throughput analysis tools at the subsystem level.
• Background in production hardware including comprehensive DFX practices (DFM/DFT/DFA/DFR), process optimization, supply chain coordination, and yield optimization at scale.
• Hands-on experience with production ramp and factory scale-up.

Why Blue Origin

At Blue Origin, we are driven by Gradatim Ferociter - "Step by Step, Ferociously." As a Senior Manufacturing Process Flow & Control DFX Engineer (Subsystem), you will design and industrialize the subsystem-level production processes building an orbital constellation at unprecedented scale, alongside world-class engineers solving problems at the intersection of advanced manufacturing, process control, and spaceflight.

Base Pay Range for:

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 [email protected]. Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.