Spacecraft represent the most pressing unmet need across the entire aerospace industry. As more launch vehicles come online and the cost to orbit decreases, more companies launching payloads to space continue to emerge. For the first time in history, this influx of payload companies combined with reduced launch costs has resulted in a massive increase in need for commercial spacecraft platforms, known as satellite buses. These buses hold the payloads of our customers and are flown on launch vehicles. Apex manufactures these satellite buses at scale using a combination of software, vertical integration, and hardware that is designed for manufacturing. Our spacecraft enable the future of society: ranging from earth observation to communications and more. Apex is seeking a Senior Electric Propulsion Engineer with deep expertise in Hall-effect thrusters to own the design, development, qualification, and production of Hall thruster technology for our electric propulsion systems. Building on Apex's in-house Hall-effect thruster capability, you will drive thruster development from plasma physics and discharge channel design through qualification, flight integration, and design-for-manufacturing at rate.
Responsibilities:
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- Own the end-to-end design and development of Apex's Hall-effect thrusters, including discharge channel geometry, magnetic circuit design, anode and gas distributor design, and thermal-mechanical packaging.
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- Develop plasma physics and performance models to drive thruster design, including ionization and acceleration behavior, magnetic field topology, efficiency, thrust-to-power, and specific impulse across the operating envelope.
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- Define and execute thruster test and life-qualification campaigns, including performance mapping, plume characterization, thermal testing, oscillation and stability characterization, wear testing, and long-duration life testing in vacuum facilities.
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- Develop erosion, degradation, and life models for the discharge channel and pole pieces and demonstrate compliance with mission life and propulsion budgets for power, thermal, throughput, and leak.
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- Drive cathode-thruster coupling and overall EP system integration in partnership with cathode, propellant feed-system, and PPU owners.
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- Select materials and processes, including ceramics, magnetic materials, and refractory metals, and qualify them for spaceflight and scalable production.
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- Optimize thruster designs for performance, mass, cost, manufacturability, and repeatability, and develop the work instructions, process flows, and AI&T procedures required to build them at rate.
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- Partner with systems, power electronics, thermal, structures, and avionics teams to define interfaces, including PPU/thruster operating points and gimbal integration, and verify requirements.
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- Support the build, integration, and test of flight hardware, as well as launch campaigns, on-orbit performance evaluation, and anomaly resolution.
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- Lead and contribute to failure analysis, root-cause investigations, and continuous design improvements to support future builds and scalable production.
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- Provide technical mentorship to propulsion engineers and contribute to the continued development of Apex's Hall thruster and electric propulsion capability.
Requirements:
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- Bachelor's degree in aerospace, mechanical, electrical, plasma/propulsion engineering, applied physics, or a related field.
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- 6+ years of relevant electric propulsion experience with a Bachelor's or Master's degree, OR a Ph.D. in electric propulsion, plasma physics, applied physics, or a closely related field with 3+ years of relevant industry experience, with substantial and demonstrable focus on Hall-effect thruster design, development, and testing.
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- Deep, hands-on knowledge of Hall thruster physics and design, including discharge channel design, magnetic circuit layout, anode and gas distribution, cathode coupling, and thermal management.
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- Experience planning and executing Hall thruster or EP test campaigns in vacuum facilities, including plasma/plume diagnostics, performance measurement, and life/wear testing.
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- Strong understanding of the failure and degradation mechanisms that drive Hall thruster life, including channel and pole erosion, thermal limits, and discharge instabilities, and how to design and test against them.
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- Working knowledge of spacecraft propulsion system architecture, propellant feed systems, and PPU interaction.
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- Experience owning hardware through design, development, build, and test.