Mechanical Engineer

Staff Mechanical Engineer, Spacecraft Engine

Astra’s mission is to improve life on Earth from space by creating a healthier and more connected planet. Today, Astra offers one of the lowest cost-per-launch dedicated orbital launch services, and one of the industry’s leading flight‑proven electric propulsion systems for satellites, the Astra Spacecraft Engine.

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.

• 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.

• 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., Solid Works, 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

• 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…