Sr. Hardware Reliability Engineer, Electrical (Starshield)

About the role

Starshield leverages SpaceX's Starlink technology and launch capability to support national security efforts. While Starlink is designed for consumer and commercial use, Starshield is designed for government use, with an initial focus on earth observation, communications, and hosted payloads.

As a Sr. Hardware Reliability Engineer for Starshield, you will play a crucial role in ensuring the reliability and performance of our satellites. You will work on identifying, analyzing, and resolving hardware failures to improve the robustness and longevity of our PCBAs. This role involves collaborating with cross-functional teams, including electrical, mechanical, software, and supply chain, to enhance the overall reliability of the Starshield hardware. This is an opportunity to work on cutting-edge R&D technology and some of the most complex applications of electrical engineering in the industry.

Responsibilities

• Responsible for troubleshooting, root cause, failure investigations, and corrective actions for Starshield production non-conforming hardware
• Utilize design schematics, test equipment, and inspection processes to identify the physics of the failure
• Take extreme ownership in containing suspect or known non-conforming products, driving root cause investigation progress and providing regular updates to technicians, production leadership, and engineering to assist in quarantine and rework activities
• Drive corrective action to products not meeting design specifications through data driven decisions using yield and defect monitoring to identify common failure modes
• Work closely with the respective test engineers for your products to keep a close feedback loop improving test assets to reduce false failures and increase test coverage
• Maximize return on investment for test and inspection processes, determining where to apply lean process checks which ensure that criteria are objective and that reliability goals are consistently met
• Identify areas for electrical design and manufacturing improvements through new product development cycles, improving final yield by applying best practices to designs and establishing repeatable process control
• Maintain thorough documentation of failure analysis findings, test results, and corrective actions
• Collaborate with on-orbit reliability team, driving timely improvements to production through on-orbit investigation findings
• Provide mentorship and guidance to more junior engineers on the team
• Serve as technical expert in electronics manufacturing processes to challenge requirements and steer the department towards value added testing

Basic Qualifications

• Bachelor's degree in electrical engineering, computer engineering, physics, or other engineering discipline
• 5+ years in hardware development, failure analysis, or reliability engineering
• 2+ years of experience with electrical test equipment (e.g., multimeters, signal generators, oscilloscopes, spectrum analyzers) used to verify hardware functionality

Preferred Skills and Experience

• Master's degree in electrical engineering or equivalent engineering discipline
• 8+ years of industry experience working with electronic hardware
• Experience with digital and mixed-signal designs, power electronics, or RF electronics using oscilloscopes, digital multimeters, power supplies, and soldering equipment
• Demonstrated experience troubleshooting and root causing electrical hardware failures
• PCBA fabrication experience (familiar with solder, flux, underfill, staking, reflow, temperature control, etc.)
• Experience with environmental testing such as HALT/HASS, thermal, vibration, and TVAC
• Experience with RF test equipment (e.g. vector network analyzer, spectrum analyzer) and concepts such as S-parameters, impedance matching, and antenna designs
• Proficiency in programming languages (e.g. Python, SQL, C, C++)
• Knowledgeable of IPC standards such as IPC-A-610G
• Experience developing or supporting any of the following products/processes:
• Analog, digital, and mixed signal circuit testing
• Design for excellence (DFX), root cause, derating, and related analyses
• RF hardware testing
• Digital communications interfaces including SPI, I2C, CAN, Ethernet, and RS422
• Statistical Process Control (SPC)
• Design of Experiments (DOE)
• Active Top Secret, Top Secret SCI, DOE Level Q clearance, or the ability and willingness to obtain one

Additional Requirements

• Able to work extended hours and weekends as needed to support critical path development and/or critical on-orbit operations
• An active clearance may provide the opportunity for you to work on sensitive SpaceX missions; if so, you will be subject to pre-employment drug and random drug and alcohol testing

Pay Range

Level 3: $140,000.00 - $205,000.00

Your actual level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills, education, and experience.

Base salary is just one part of your total rewards package at SpaceX. You may also be eligible for long-term incentives, in the form of company stock or long-term cash awards, as well as potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan.

You will also receive access to comprehensive medical, vision, and dental coverage, access to a 401(k) retirement plan, short and long-term disability insurance, life insurance, paid parental leave, and various other discounts and perks. You may also accrue 3 weeks of paid vacation and will be eligible for 10 or more paid holidays per year.

Employees accrue paid sick leave pursuant to Company policy which satisfies or exceeds the accrual, carryover, and use requirements of the law.

Those with an active clearance will receive a 10% differential, up to an additional $20,000 annually, once officially briefed into a classified program.

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.