TCA Mechanical Design Engineer Level 1

Cowboy Space Corp. is building the infrastructure to power and connect the orbital economy. Our satellites operate in Low Earth Orbit to collect sunlight and enable a new class of capabilities—from powering on-orbit compute, to transmitting energy via infrared lasers (space-to-earth and space-to-space), to delivering secure, high-bandwidth optical data. By rethinking how energy and data are generated and distributed in space, we’re unlocking entirely new ways to operate both in orbit and on Earth.

Founded in 2024 by Baiju Bhatt (co-founder of Robinhood), Cowboy Space Corp. is backed by leading investors and built by a team from top aerospace and defense organizations. We’re moving quickly to solve complex technical challenges and build a new category of space infrastructure.

About the Role:

We are seeking a TCA Mechanical Design Engineer Level 1 who is eager to build depth in manufacturing processes, tooling design, and specialized fabrication methodologies for rocket engine injector, combustion chamber, and nozzle development. The ideal candidate pairs a strong mechanical engineering foundation with hands-on shop and lab experience from internships, co-ops, or student design-build-test teams. This is a real ownership role from day one: you will own TCA hardware through rapid design/build/test cycles, with senior TCA engineers to learn from. You will work closely with propulsion, structures, thermal, materials and processes, manufacturing, and test operations. This position is located onsite in Kent, WA.

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 — hand calculations, thermal and structural FEA, and tolerance stack-ups

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

Release production-ready models, drawings, specifications, and release documentation

Work directly with machinists, welders, and technicians on the shop floor to close the loop between design intent and what actually gets built

Basic Qualifications

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

1+ years of experience in mechanical design for rocket engine or comparable high-performance hardware. Internships, co-ops, and competition or research team experience count.

Strong mechanical design proficiency with DFM/DFA emphasis, leading to hands-on fabrication, assembly or component manufacturing experience

Proficiency with 3D CAD (NX, SolidWorks, CATIA, or Creo), structural analysis tools, and creating engineering drawings to ASME Y14.5 GD&T standards

Strong fundamentals in thermodynamics, fluid dynamics, and structural mechanics

Must be a U.S. citizen or national, lawful permanent resident, 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

Preferred Qualifications

2+ years of experience with rocket engine TCA hardware, including component lifecycle ownership through production

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

Design for Additive Manufacturing (DfAM) experience

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

Master's degree in an engineering discipline