Sr. Materials Engineer, Metals (Starlink)

About the role

At SpaceX, we're leveraging our rocket and spacecraft expertise to deploy Starlink, the world's largest and most advanced satellite constellation, delivering fast internet to over 10 million users worldwide. We design, build, test, and operate the full system - from thousands of satellites to user terminals and software.

We're revolutionizing the launch market through rapid reusability and cutting-edge technology. As a Sr. Materials Engineer, you'll take a hands-on role in developing, implementing, and troubleshooting advanced material systems. You'll use your expertise, experience, and creativity to solve complex material selection and processing challenges as we scale Starlink for high-volume production.

Responsibilities

• Provide materials selection, characterization, qualification, and manufacturing process support for metallic and metal-joined (welded, brazed, soldered) hardware on Starlink satellites and ground infrastructure assemblies.
• Develop mechanical and physical properties of metallic alloys and joints for the design community, including data, allowables, and process recommendations.
• Perform root cause investigations and failure analysis using fractography, metallography, SEM-EDS, optical microscopy, and other characterization testing.
• Develop, qualify, troubleshoot, and optimize metal joining processes (welding, brazing, soldering, sintering) used in production, including understanding of process variables and resulting material performance.
• Provide technical review and advising for design efforts as it relates to material alloy selection, material & process specifications, fracture requirements, and design-for-manufacturability.
• Collaborate with suppliers on qualification, property development, and issue resolution for custom-manufactured forgings, castings, and other metallic components.

Basic Qualifications

• Bachelor's degree in Materials Science, Materials Engineering, Welding Engineering, Metallurgical Engineering, or other Materials Engineering discipline.
• 5+ years of experience with aluminum alloys used for structural and non-structural applications; metal alloys used in electronic applications; and metal-joining processes (welding, brazing, soldering, sintering).

Preferred Skills and Experience

• Master's or PhD in Material Science, Materials Engineering, Weld Engineering, Metallurgical Engineering, or other Materials Engineering discipline.
• Experience with characterization techniques and equipment, including SEM-EDS, optical microscopy, hardness testers, mechanical property testing, and spectroscopy techniques for composition or phase.
• Strong interpersonal and collaborative skills with enthusiasm for the team's spirit of innovation in cutting-edge technology.
• First principles understanding of welding processes, weld strength testing methodologies, and standards used to make informed welding decisions.
• Hands-on experience with metal-joining technologies (welding, brazing, soldering, sintering) in a high-production manufacturing environment.
• Experience with failure analysis, materials testing labs, ASTM/NASA/AMS specs, or supplier management.
• Experience with technical review of materials and processes and a sound understanding of the interaction between process variables and the resulting material performance.
• Demonstrated track record of success in a rapidly growing, fast-paced, highly competitive, and scrappy entrepreneurial environment that operates under tight timelines and aggressive schedules.
• Effective written and interpersonal communication skills.

Additional Requirements

• Willingness to travel to other SpaceX sites and/or vendors for significant or extended periods (up to 25%).
• Ability to lift up to 30 lbs unassisted.
• Ability to stand/walk for long periods of time.
• Willingness to work long hours and weekends as needed to support manufacturing and test campaigns.

Pay Range

Level 3: $135,000.00 - $220,000.00

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 in Washington State accrue paid sick time in compliance with state and federal law. Company shuttles are offered to employees for roundtrip travel from select Seattle locations to the SpaceX Redmond office Monday to Friday.

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.