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Staff Mechanical Engineer, Spacecraft Engineer

Alameda, CA 94501

Posted: 09/22/2025 Employment Type: Direct Industry: Engineering Job Number: 85968

Job Description

We are seeking a Staff Mechanical Engineer to lead the mechanical design and manufacturability of next-generation Hall-effect thrusters for spacecraft propulsion. This position is critical in ensuring propulsion systems achieve world-class performance and reliability in orbit, while also being optimized for repeatable, cost-effective, and scalable production.

The ideal candidate combines deep expertise in mechanical design for extreme environments with a proven ability to apply design-for-manufacture (DFM) and design-for-assembly (DFA) principles. This is a leadership role with direct impact on the design, integration, and qualification of propulsion hardware that must survive launch and operate reliably for years in space.

Key Responsibilities
  • Own the mechanical architecture of Hall-effect thrusters, including discharge channels, magnetic circuits, and electrode assemblies
  • Drive DFM/DFA practices to scale hardware from prototypes into high-volume production
  • Specify advanced materials, coatings, and joining methods suitable for plasma environments and long-duration missions
  • Perform structural, thermal, and dynamic analyses to validate designs against launch and space environments
  • Collaborate with suppliers and manufacturing teams to resolve producibility challenges and qualify vendors
  • Lead and support mechanical testing campaigns (vibration, shock, thermal-vacuum, life testing) for flight hardware
  • Partner with plasma physics, electrical, and systems engineering teams to ensure integrated thruster performance
  • Mentor engineers, review designs, and serve as subject matter expert in manufacturable spacecraft propulsion hardware
  • Champion continuous improvement to simplify, standardize, and modularize designs for reduced cost and faster production cycles
Compensation
  • Base salary range: $150,000 - $185,000 per year (Bay Area market range; excludes bonuses and benefits)

Job Requirements

Minimum Qualifications
  • Bachelor's or Master's degree in Mechanical, Aerospace, or related engineering field
  • 5+ years of experience in mechanical design of aerospace hardware (propulsion or high-reliability spacecraft systems)
  • Expertise in structural, thermal, and materials design considerations for spaceflight hardware
  • Proven track record applying DFM/DFA principles to aerospace hardware transitioned into production
  • Proficiency with CAD and analysis tools (SolidWorks, Creo, NX, ANSYS, or equivalent)
  • Hands-on experience with qualification testing (vibration, shock, thermal-vacuum)
  • Familiarity with aerospace standards (NASA, ESA, ECSS, MIL-STD, or equivalent)
  • Strong communication and leadership skills with ability to mentor teams and influence system-level decisions
Preferred Skills / Multipliers
  • Direct experience with electric propulsion hardware (Hall-effect thrusters, ion engines)
  • Knowledge of high-temperature materials, ceramics, or coatings for plasma-facing components
  • Experience scaling hardware from development units to flight production
  • Familiarity with additive manufacturing or advanced manufacturing techniques for propulsion
  • Previous leadership as a mechanical lead or system architect for flight-qualified hardware
Other Requirements
  • Must meet ITAR/EAR compliance as a U.S. Person (citizen, permanent resident, refugee, or asylee) or be eligible for licensing
  • Subject to background checks and, if applicable, government contract clearance
  • Applicants in San Francisco will be considered consistent with the Fair Chance Ordinance
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About Alameda, CA

Ready to kickstart your career in the vibrant and thriving area around Alameda, California? This picturesque region, nestled in the San Francisco Bay Area, offers an abundance of job opportunities with a backdrop of stunning views and a rich cultural scene. Discover the charm of Alameda with its historic landmarks like the USS Hornet Museum, unique cuisine at Alameda's vibrant restaurants, and diverse entertainment options at venues like the Alameda Theatre & Cineplex. With easy access to outdoor activities at Crown Memorial State Beach and the Alameda Marina, this area provides the perfect blend of work and play. Explore our job listings today and make your mark in this enchanting location!