Propulsion Build Engineer (Starship)

About the role

The Propulsion Build Engineer role is responsible for developing build processes, tooling, and designs for manufacturability that will enable high rate manufacturing of vehicle fluid systems. This role will involve heavy engagement with both the design teams and the build teams across the program. The role demands close interaction with the Starship and Super Heavy hardware, including participating in and driving the physical builds and installation of the propulsion systems.

Propulsion Build Engineers will be highly engaged in the fabrication of a wide range of pressurized components and systems, including designing tooling (assembly aide, welding, part fixturing, etc.) and processes (welding, tube bending, pipe fitting, large part movement, and large structure integration) to rapidly build the Starship and Super Heavy vehicles.

The role can include designing pressurized test setups, working with cryogenic fluids, and executing testing and data review. Further along in the build, this role will be responsible for items such as integration operations sequencing, and working with technicians on installing flight-critical hardware on the vehicle.

Propulsion Build Engineers will be expected to sometimes act as de-facto supervisors and advisors to production technicians, welders, and other skilled labor partners.

Responsibilities

• Develop manufacturing processes, techniques, and tools to enable efficient and high rate manufacturing
• Work with the design engineering team to drive simplicity into the vehicle fluids systems at every level
• Guide a team of technicians, welders, and fabricators in building high quality and functional fluid systems hardware
• Coordinate and execute development, qualification, and acceptance testing of systems and tooling needed to meet hardware deadlines
• Create original CAD models and prints for flight and/or tooling components
• Create and maintain build schedules
• Participate in design reviews internally and with suppliers and customers
• Partner with engineering & production teams to generate ideas, designs, and improvements for current and next-generation vehicles

Basic Qualifications

• Bachelor's or advanced degree in aerospace engineering, manufacturing engineering, materials engineering, mechanical engineering, or other engineering discipline
• Hands-on project experience with fluid and/or mechanical systems
• 1+ years of manufacturing design experience (internship and academic experience is applicable)

Preferred Skills and Experience

• 2+ years of experience with GD&T concepts
• Experience with fluid mechanics, incompressible and compressible flow, and heat transfer
• Experience with pressurized components (valves, regulators, tubes, pipes, etc.)
• Experience with mechanical design, including basic structures and fluids calculations and design considerations
• Process development, facility and line layouts, error-proofing
• Experience with Unigraphics NX and Teamcenter CAD and PLM systems
• Detailed knowledge of Siemens NX or similar CAD and PLM packages
• Prior experience with developing, maintaining, and improving welding processes
• Experience with automated and manual welding processes for piping and structural applications

Additional Requirements

• Ability to work extended hours and weekends as necessary
• Flight hardware typically is built in tight quarters and physical dexterity is required
• Ability to perform job duties that require standing, kneeling, crouching, twisting upper body, working in cramped positions in small openings and climbing hand over hand
• Typically exposed to work in extreme outdoor environments - heat, cold, rain
• Work performed in an environment requiring exposure to fumes, odors, and noise
• Schedule varies depending on site operational needs; flexibility required
• Flexibility to travel to remote build sites, up to 10%

Itar Requirements

• To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.