Staff Mechanical Engineer

Staff Mechanical Engineer

We are looking for a Staff Mechanical Engineer to lead the mechanical design and manufacturability of next-generation Hall-effect thrusters for spacecraft propulsion. This role is critical to ensuring that our propulsion systems not only achieve world-class performance and reliability in orbit but are also optimized for repeatable, cost-effective, and scalable production. The ideal candidate will blend deep expertise in mechanical design for extreme environments with a proven ability to drive design-for-manufacture (DFM) and design-for-assembly (DFA) principles into hardware that must survive launch and operate for years in space.

How You'll Fulfill Your Mission

• Thruster Mechanical Architecture: Own and develop the structural and thermal design of Hall-effect thruster components including discharge channels, magnetic circuits, and electrode assemblies.
• Design for Manufacturability: Drive DFM/DFA practices across the thruster hardware, ensuring scalability from prototype to high-volume production.
• Material & Process Selection: Evaluate and specify advanced materials, coatings, and joining methods compatible with high-temperature plasma environments and long-duration missions.
• Analysis & Verification: Perform structural, thermal, and dynamic analyses to validate designs against launch loads, thermal cycles, and space environmental factors.
• Supplier Engagement: Collaborate with manufacturing and supply chain partners to mature designs, resolve producibility challenges, and qualify vendors.
• Testing & Qualification: Define and support mechanical testing campaigns (vibration, shock, thermal-vacuum, life testing) to ensure compliance with flight requirements.
• Cross-functional Collaboration: Work closely with plasma physics, electrical, and systems engineering teams to balance mechanical design with thruster performance, integration, and mission needs.
• Leadership: Mentor mechanical and propulsion engineers, review critical designs, and act as a subject matter expert in manufacturable spacecraft propulsion hardware.
• Continuous Improvement: Lead efforts to simplify, standardize, and modularize thruster designs for reduced cost, improved reliability, and faster production cycles.

Why We Value You

• 5+ years of experience in mechanical design of aerospace hardware, including propulsion or high-reliability spacecraft systems
• Deep expertise in mechanical design for spaceflight hardware, including structural, thermal, and materials considerations
• Proven track record of applying DFM/DFA principles to aerospace hardware that transitioned successfully into production
• Proficiency with CAD and analysis tools (e.g., SolidWorks, Creo, NX, ANSYS, or equivalent)
• Hands-on experience with qualification testing for flight hardware (vibration, shock, thermal-vacuum)
• Familiarity with spaceflight standards and certification processes (NASA, ESA, ECSS, MIL-STD, or equivalent)
• Strong communication and leadership skills, with the ability to influence system-level decisions and mentor teams
• Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, or a related field

Desired Multipliers

• Direct experience with electric propulsion hardware, particularly Hall-effect thrusters or ion engines
• Background in high-temperature materials, ceramics, or coatings for plasma-facing components
• Experience scaling hardware from engineering development units to flight production at quantity
• Familiarity with additive manufacturing or other advanced manufacturing techniques for propulsion systems
• Previous experience serving as a mechanical lead or system architect for flight hardware

The pay range for this role is: $150,000 - $185,000 per year. The stated compensation range reflects only the targeted base salary range in the San Francisco Bay Area and excludes additional earnings such as bonus and benefits. If your salary requirements fall outside of the range, we still encourage you to apply. You do not need to match every listed expectation to apply for this position. Here at Astra, we know that diverse perspectives foster the innovation we need to be successful, and we are committed to building a team that encompasses a variety of backgrounds, experiences, and skills. San Francisco Applicants: Astra will consider applicants with arrest and conviction records (criminal histories) in a manner consistent with the San Francisco Fair Chance Ordinance. ITAR Requirements: This position requires compliance with U.S. Government space technology trade restrictions, specifically the International Trafficking in Arms Regulations (ITAR), Export Administration Regulations (EAR) and additional regulations governing satellite, launch vehicle, missile, and other related technologies. All jobs restricted by these regulations will be contingent upon the applicant's status as a documented U.S. Person or their ability to receive a trade license from the cognizant government agency; in addition to any required company background checks and in compliance with applicable U.S. and California laws. Similarly, positions requiring the ability to work on government contracts or a security clearance are also contingent upon the applicants ability to receive the appropriate clearance and be allowed to work on U.S. government contracts.