Staff Mechanical Engineer – Space Propulsion (Hall Effect Thrusters)

Location: Alameda, San Francisco
Job Type: Full-Time| On Site | Senior/Staff Level

About the Role

We’re hiring a Staff Mechanical Engineer to lead the mechanical design, analysis, and production readiness of next-generation Hall Effect Thrusters. This role owns the mechanical architecture for high-reliability space hardware that must survive launch, operate for years in orbit, and be manufacturable at scale.

Key Responsibilities

• Own structural, thermal, and mechanical design of Hall effect thruster components.

• Define mechanical layout, tolerances, and producibility standards.

• Lead material selection for ceramics, high-temp alloys, and plasma-facing components.

• Drive DFM/DFA and improve manufacturability for higher-volume production.

• Perform structural, thermal, vibration, and modal analyses.

• Support environmental and qualification testing (TVAC, vibe, shock, life tests).

• Collaborate with plasma physics, propulsion, electrical, systems, and production teams.

• Provide technical leadership, mentorship, and design review support.

Required Qualifications

• 5+ years designing aerospace or high-reliability flight hardware.

• Strong structural & thermal design background for extreme environments.

• Experience taking hardware from prototype to production.

• Proficiency with CAD/FEA tools (SolidWorks, NX, Creo, ANSYS).

• Hands-on experience with flight qualification testing.

• Familiar with NASA/ESA/ECSS/MIL-STD standards.

• Degree in Mechanical or Aerospace Engineering.

Preferred Experience

• Hall effect or ion propulsion systems.

• Ceramic or high-temperature material design.

• Scaling propulsion hardware into manufacturing.

• Advanced manufacturing (AM, brazing, coatings).

• Prior mechanical lead on flight hardware.

Darwin Recruitment is acting as an Employment Agency in relation to this vacancy.

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