B.Sc. in Chemical Engineering, Materials Science, Mechanical Engineering, or related field
5+ years in encapsulation, lamination, or packaging process development for photovoltaic or flexible electronics
Proven experience in developing lamination or sealing processes
Strong grasp of polymer processing and aging mechanisms
Experience in accelerated aging test design and lifetime prediction methodologies
Proficient with process characterization tools like DSC, TGA, and optical microscopy
Track record of scaling encapsulation processes from development to production
Responsibilities
Develop lamination processes for solar module encapsulation, focusing on temperature and pressure control
Qualify encapsulant materials to ensure compatibility with device stacks
Collaborate on thin-film encapsulation processes using PECVD and ALD
Design accelerated aging studies simulating space environments
Optimize edge-sealing processes for long-term reliability
Establish inline monitoring and acceptance criteria for encapsulation
Conduct failure analysis on degraded modules
Create process documentation and capability studies for encapsulation steps
Scale processes from coupon-level to full module format
Interface with equipment vendors for lamination and sealing tools
Benefits
Medical, dental, and vision insurance
Paid parental leave and short/long-term disability
401(k) with up to 5% company match
Education Support Program
Stock options for regular employees
Up to four weeks of paid time off and 14 company-paid holidays
Potential for bonuses based on individual contributions and company performance
Full Job Description
Application close date: Applications will be accepted on an ongoing basis until the requisition is closed.
About the Role
You will own the encapsulation process development pipeline: from lamination and edge-sealing process recipes through inline quality verification to accelerated lifetime qualification. You will develop the process parameters, equipment configurations, and quality controls that turn packaging designs into repeatable manufacturing. You will be the bridge between packaging design intent and fabrication reality.
Responsibilities
Develop lamination processes for solar module encapsulation: temperature profiles, pressure schedules, atmosphere control, and cure protocols compatible with thermally sensitive perovskite layers
Qualify encapsulant materials (EVA, POE, ionomer, silicone, thermoplastic polyurethane, etc) for compatibility - ensuring no chemical interaction with the device stack in fabrication and throughout operation.
Develop and validate thin-film encapsulation processes (PECVD, ALD-based barriers) in collaboration with other team members
Design and execute accelerated aging studies for the environments in space and on the way to the launch pad: humidity, thermal cycling, UV exposure, particle radiation, and electrostatic buildup
Optimize edge-sealing processes (desiccant-filled edge seals, laser-sealed glass, butyl rubber, UV-cure adhesives) for hermeticity and long-term reliability
Establish inline process monitoring and acceptance criteria for encapsulation steps (optical inspection, leak testing, adhesion pull tests)
Perform failure analysis on degraded or failed modules
Develop process documentation, SPC charts, and process capability studies for each encapsulation step
Scale encapsulation processes from coupon-level to full module format
Interface with equipment vendors to specify and commission lamination, sealing, and barrier deposition tools
Work with your customers on the broader solar array product team to provide a product that is compatible with integration at-scale, for small (several kW) to large (100kW+) array designs
Minimum Qualifications
B.Sc. Chemical Engineering, Materials Science, Mechanical Engineering, or related field
5+ years of experience in encapsulation, lamination, or packaging process development for photovoltaic, OLED, or flexible electronics applications
Demonstrated experience developing lamination or sealing processes
Strong understanding of polymer processing: glass transition, crosslinking kinetics, adhesion science, and aging mechanisms
Experience with accelerated aging test design and lifetime prediction methodologies
Proficiency with process characterization tools: DSC, TGA, DMA, peel testing, optical microscopy, moisture sensors
Track record of transferring encapsulation processes from development to production-representative scale
Preferred Qualifications
Direct experience encapsulating silicon, CdTe, CIGS, perovskite, or organic photovoltaic devices (understanding of thermal and chemical sensitivity constraints)
Experience with thin-film barrier encapsulation (ALD, PECVD, or hybrid organic-inorganic barriers)
Direct experience with encapsulation designs for the space-environment and its unique degradation mechanisms (UV, proton/electron radiation, thermal cycling, atomic oxygen)
Experience with glass-glass lamination, laser edge sealing, or hermetic packaging for electronics
Familiarity with qualification test standards
Experience with inline metrology and automated process control for lamination lines
Understanding of water vapor and oxygen permeation modeling for lifetime prediction
Base Pay Range for: WA applicants is $145,188.00 - $203,263.20
Other site ranges may differ
Culture Statement
Don't meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you're excited about this role but your past experience doesn't align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.
Benefits
Benefits include: Medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability, 401(k) with a company match of up to 5%, and an Education Support Program.
Stock Options for all regular employees (working at least 20 hours/week)
Paid Time Off: Up to four (4) weeks per year based on weekly scheduled hours, and up to 14 company-paid holidays.
Dependent on role type and job level, employees may be eligible for benefits and bonuses based on the company's intent to reward individual contributions and enable them to share in the company's results, or other factors at the company's sole discretion. Bonus amounts and eligibility are not guaranteed and subject to change and cancellation. Please check with your recruiter for more details.
About Blue Origin
Blue Origin is an aerospace company that develops rockets and spacecraft for commercial and government customers. The company's products include the New Shepard suborbital vehicle and the New Glenn orbital rocket. Blue Origin was founded in 2000 by Jeff Bezos and is headquartered in Kent, Washington.
