Propulsion Manufacturing Engineer

Overview

Propulsion Manufacturing Engineer at AST Space Mobile. We are seeking a highly skilled engineer to support the design, assembly, integration, and testing of electric propulsion thrusters for Low Earth Orbit (LEO) satellite applications. The candidate will have hands-on experience with propulsion system hardware, electrical and plasma thrusters, and production line processes to ensure reliable, repeatable, and high-quality manufacturing.

• Develop and maintain manufacturing processes for electric propulsion thrusters and subsystems, including assembly, bonding, welding, and integration.
• Support production line setup, tooling design, and workflow optimization to improve yield, cycle time, and throughput.
• Collaborate with design engineers to ensure manufacturability of propulsion system components and assemblies.
• Define and implement quality control procedures including ESD protection, contamination control, vacuum compatibility, and leak testing.
• Support the assembly, integration, and verification (AIV) of propulsion modules, including electrical connections, harness routing, and fluid/electrical interfaces.
• Troubleshoot and resolve issues related to plasma thrusters, ion engines, Hall-effect thrusters, and PPU integration.
• Conduct DFM/DFX reviews to enhance reliability and manufacturability.
• Develop detailed work instructions, assembly documentation, and test procedures for technicians and operators.
• Participate in qualification and acceptance testing, including vibration, thermal vacuum (TVAC), and functional testing of thruster subsystems.
• Drive continuous improvement initiatives for cost reduction, process automation, and scalability for satellite constellations.

• Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, Electrical Engineering, or related field.
• Hands-on experience with electric propulsion systems (Hall thrusters, ion thrusters, or similar plasma propulsion technologies).
• Familiarity with vacuum chamber operations, leak detection methods, and contamination control.
• Experience with satellite manufacturing standards (ECSS, NASA, IPC, or equivalent).
• Strong knowledge of electrical integration, power processing units (PPUs), and harnessing in propulsion systems.
• Proficiency in CAD software (CATIA, NX, Solid Works, or similar) for design-for-manufacturing activities.
• Knowledge of manufacturing processes such as precision machining, brazing, welding, additive manufacturing, and surface treatments.
• Strong problem-solving, documentation, and cross-disciplinary collaboration skills.
• Experience in cleanroom and ESD-controlled environments is highly desirable.

• Previous experience in LEO satellite propulsion integration.
• Familiarity with thruster lifetime testing and endurance campaigns.
• Understanding of propellant systems (Xenon, Krypton, or alternative propellants).
• Knowledge of automation and digital manufacturing tools.

AST Space Mobile is an Equal Opportunity, at-will employer; employment is governed on the basis of merit, competence and qualifications and will not be influenced by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, or any other legally protected status.