Director of DFX, Design for Manufacturing Mechanical

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 TeraWave Operations is architecting a first-of-its-kind satellite connectivity manufacturing capability, and we are seeking a Director of DFX, Design for Manufacturing Mechanical to shape how it is built.

You will be at the center of translating cutting-edge hardware designs into scalable, high-quality manufacturing processes - from NPI through full rate production - while driving Design for Excellence principles across mechanical systems including Design for Assembly, Design for Manufacturability, mechanical tolerancing, structural design optimization, and Design for Reliability at the component and assembly level. Working in close partnership with engineering, product, and operations leadership, you will ensure that what we design can be manufactured with precision, reliability, and velocity at scale.

What You Will Do

• Define and own the DFM and DFX - Mechanical strategy, guiding programs from the earliest concept stages through mass production
• Champion DFX principles across mechanical systems - DFA, DFM, DFR, and DFC - embedding them deeply into the product development process before design decisions become costly to reverse
• Spearhead NPI efforts including prototype builds, prototype facility stand-up, factory line development, and the seamless transition to full rate production
• Serve as a strategic partner to hardware engineering teams, leveraging simulation, tolerance stack-up analysis, GD&T, and DOE to drive design decisions that elevate manufacturability, testability, reliability, yield, and cost performance
• Architect and scale factory automation strategies - including modular and reconfigurable approaches - to accelerate production ramp across varying program volumes
• Recruit, develop, and inspire a world-class DFM and DFX engineering team, cultivating a culture of technical excellence and continuous improvement
• Establish robust manufacturing assembly processes spanning mechanical, electronic, molding, stamping, forming, and machining disciplines
• Define and enforce rigorous mechanical DFX review gates throughout the product development lifecycle, proactively identifying and eliminating tolerance, assembly, and reliability risks before they reach the factory floor
• Lead failure analysis and corrective action processes that drive measurable improvements in quality, throughput, and FPY outcomes
• Collaborate with global supply chain and supplier partners to align on process requirements and manufacturing readiness at every stage
• Define, track, and communicate key manufacturing and DFX metrics, translating operational performance into clear insights for senior leadership

What You Bring

• 15+ years of experience in consumer electronics or hardware manufacturing engineering, including at least 5 years in a senior leadership role
• Exceptional depth in NPI, prototype facility stand-up, factory line development, and manufacturing assembly across complex mechanical and electronic systems
• A distinguished track record of applying mechanical DFX methodologies - DFM, DFA, DFR, GD&T, tolerance stack-up analysis, and statistically based DOE - across high-complexity hardware programs
• Demonstrated success standing up manufacturing operations and prototype facilities from the ground up and scaling them to high volume production
• Commanding expertise in factory automation, failure analysis, process development, and yield improvement with measurable cost savings and FPY results to show for it
• A proven ability to shape product design decisions early in the development cycle, mitigating downstream manufacturing and quality risk before it materializes
• A history of building and leading high-performing, globally distributed engineering organizations
• A collaborative, cross-functional mindset with deep experience partnering across product, engineering, supply chain, and operations
• Exceptional communication skills and executive presence with the ability to influence and inspire across all levels of an organization

Nice to Have

• Experience in satellite, aerospace, or defense hardware manufacturing
• Background in high-precision mechanical assembly manufacturing for complex hardware programs
• Multilingual capabilities supporting global supplier and manufacturing partner relationships
• Experience managing programs across US and Asia-based manufacturing sites
• Hands-on proficiency with mechanical simulation, tolerance analysis tools, and structured design review processes such as DFMEA for mechanical assemblies

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 (CDL drivers only), 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.