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)
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