Senior TCA Mechanical Design Engineer

Background
Cowboy Space Corporation is building the infrastructure to power and connect the orbital economy. Our modular, scalable satellites collect sunlight in Low Earth Orbit to enable multiple integrated applications: transmitting energy via infrared lasers (space-to-earth and space-to-space), powering on-orbit high-performance computing clusters (GPU/TPU), and providing secure, high bandwidth optical data transport.
Current energy and data systems rely on complex logistics and outdated infrastructure. Cowboy Space Corporation overcomes these challenges by enabling direct, on-demand, secure, and scalable energy distribution and data processing from space. This will revolutionize how we operate in orbit and on Earth, supporting the rapidly expanding space industrial base, ISAM (In-Space Servicing, Assembly, and Manufacturing) operations, remote regions, and military bases.
Baiju Bhatt founded Cowboy Space Corporation in 2024. Inspired by his father’s work with NASA Langley Research Center, Baiju earned his B.S. in Physics and M.S. in Mathematics at Stanford before co-founding Robinhood, now a public company that has helped over 20 million Americans access the financial system. Cowboy Space Corporation has raised ~$365 million from Index Ventures, Interlagos, Construct Ventures, Breakthrough Energy Ventures, Andreessen Horowitz, NEA, and others.
This is an ambitious mission that demands extraordinary talent. Cowboy Space Corporation ’s team has worked at places like SpaceX, Blue Origin, Stoke Space, Astranis and NASA, and is based in San Carlos, CA. If you're ready to solve complex technical challenges and help build the most important energy company in the world, we want to hear from you.

About the Role:

We are seeking a Senior TCA Mechanical Design Engineer with deep expertise in manufacturing processes, tooling design, and specialized fabrication methodologies to support rocket engine injector, combustion chamber, and nozzle development. The ideal candidate combines advanced mechanical design capabilities with hands-on manufacturing expertise to drive rapid design/build/test cycles. This position is located onsite in the greater Seattle, WA area.

Responsibilities:

• Own end-to-end TCA hardware lifecycle from requirements through manufacturing to flight qualification

• Lead mechanical design optimized for manufacturability, applying physics-based analysis

• Implement advanced manufacturing techniques: additive manufacturing, precision CNC machining, EDM, and specialized joining (e.g. laser welding, vacuum brazing, diffusion bonding)

• Design tooling, fixtures, and work-holding solutions for rapid development and repeatable production

• Develop and qualify manufacturing process parameters for novel materials and geometries

• Plan and execute hotfire test campaigns, analyze results, and lead rapid redesign efforts balancing performance with manufacturing constraints

Basic Qualifications:

• Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering

• Strong mechanical design proficiency with DFM/DFA emphasis

• Hands-on experience with CNC machining, welding/brazing, or additive manufacturing

• Technical proficiency in thermodynamics, fluid dynamics, and structural mechanics

Preferred Qualifications:

• Rocket engine TCA component lifecycle ownership including production

• Design for Additive Manufacturing expertise

• Precision machining knowledge: 5-axis CNC, high-speed machining, Swiss machining

• Specialized joining expertise: vacuum brazing, electron beam/laser welding, friction stir welding

• Tooling design: fixtures, EDM electrodes, CMM/welding fixtures

• Ansys Mechanical, Fluent, or Thermal Desktop experience

• Advanced degree in engineering discipline

Compensation and Benefits

The salary range for this position is $185,000 – $210,000 annually. The actual base salary offered will depend on factors such as job-related skills, experience, qualifications, and internal equity.

• Equity in Cowboy Space Corp.

• 401(k) retirement savings plan

• Paid time off

• 10 paid holidays per calendar year

• Paid parental leave

• Relocation assistance if applicable

ITAR Requirements

• Export Control Requirement: To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR), applicants must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Learn more about ITAR here.