Propulsion Manufacturing Engineer

AST SpaceMobile is building the first and only global cellular broadband network in space to operate directly with standard, unmodified mobile devices based on our extensive IP and patent portfolio and designed for both commercial and government applications. Our engineers and space scientists are on a mission to eliminate the connectivity gaps faced by today’s five billion mobile subscribers and finally bring broadband to the billions who remain unconnected.

Position Overview

We are seeking a highly skilled Propulsion Manufacturing Engineer to support the design, assembly, integration, and testing of electric propulsion thrusters for Low Earth Orbit (LEO) satellite applications. The ideal 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.

Key Responsibilities

• 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.

Qualifications

• 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, SolidWorks, 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.

Preferred Skills

• 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.

This job description may not be inclusive to the duties and responsibilities listed. Additional tasks may be assigned to the employee from time to time or the scope of the job may change as needed by business demands.

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