Sr. TCA Mechanical Design Engineer

Cowboy Space Corp. is building the infrastructure to power and connect the orbital economy. Our satellites operate in Low Earth Orbit to collect sunlight and enable a new class of capabilities-from powering on-orbit compute, to transmitting energy via infrared lasers (space-to-earth and space-to-space), to delivering secure, high-bandwidth optical data. By rethinking how energy and data are generated and distributed in space, we’re unlocking entirely new ways to operate both in orbit and on Earth.

Founded in 2024 by Baiju Bhatt (co-founder of Robinhood), Cowboy Space Corp. is backed by leading investors and built by a team from top aerospace and defense organizations. We’re moving quickly to solve complex technical challenges and build a new category of space infrastructure.

About the Role:

We are seeking a Senior TCA Mechanical Design Engineer with deep expertise in manufacturing processes, tooling design, and specialized fabrication methodologies to support rocket engine injector, combustion chamber, and nozzle development. The ideal candidate combines advanced mechanical design capabilities with hands-on manufacturing expertise to drive rapid design/build/test cycles. This position is located onsite in the greater Seattle, WA area.

Responsibilities:

• Own end-to-end TCA hardware lifecycle from requirements through manufacturing to flight qualification

• Lead mechanical design optimized for manufacturability, applying physics-based analysis

• Implement advanced manufacturing techniques: additive manufacturing, precision CNC machining, EDM, and specialized joining (e.g. laser welding, vacuum brazing, diffusion bonding)

• Design tooling, fixtures, and work-holding solutions for rapid development and repeatable production

• Develop and qualify manufacturing process parameters for novel materials and geometries

• Plan and execute hotfire test campaigns, analyze results, and lead rapid redesign efforts balancing performance with manufacturing constraints

Basic Qualifications:

• Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering

• Strong mechanical design proficiency with DFM/DFA emphasis

• Hands-on experience with CNC machining, welding/brazing, or additive manufacturing

• Technical proficiency in thermodynamics, fluid dynamics, and structural mechanics

Preferred Qualifications:

• Rocket engine TCA component lifecycle ownership including production

• Design for Additive Manufacturing expertise

• Precision machining knowledge: 5-axis CNC, high-speed machining, Swiss machining

• Specialized joining expertise: vacuum brazing, electron beam/laser welding, friction stir welding

• Tooling design: fixtures, EDM electrodes, CMM/welding fixtures

• Ansys Mechanical, Fluent, or Thermal Desktop experience

• Advanced degree in engineering discipline

Compensation and Benefits

The salary range for this position is$185,000 - $210,000 annually. The actual base salary offered will depend on factors such as job-related skills, experience, qualifications, and internal equity.

• Equity in Cowboy Space Corp.

• Employees and their eligible dependents may enroll in medical, dental, and vision insurance

• 401(k) retirement savings plan

• Paid time off

• 10 paid holidays per calendar year

• Paid parental leave

• Relocation assistance if applicable

• Daily lunch in the office and a fully stocked kitchen with beverages and snacks

ITAR Requirements

• Export Control Requirement: To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), applicants must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Learn more about ITAR here.

Disclaimer

This job description is a summary of the primary duties and responsibilities of the job and position. It is not intended to be a comprehensive or all-inclusive listing of duties and responsibilities. Contents are subject to change at Cowboy Space Corp.’s discretion.

Cowboy Space Corp. is an equal employment opportunity employer. We consider individuals for employment or promotion according to their skills, abilities and experience. Cowboy Space Corp. is committed to complying with all applicable laws prohibiting discrimination based on race, color, religious creed, age, national origin, ancestry, physical, mental or developmental disability, sex (which includes pregnancy, childbirth, breastfeeding and medical conditions relating to pregnancy, childbirth or breastfeeding), veteran status, military status, marital or registered domestic partnership status, medical condition (including cancer or genetic characteristics), genetic information, gender, gender identity, gender expression, sexual orientation, as well as any other category protected by federal, state or local laws.