Sr. Mechanical Process Engineer, PCB (Starlink/Starmind)

About the role

SpaceX is leveraging our experience building rockets and spacecraft to deploy Starlink, the world's largest satellite constellation and most advanced broadband internet system.

We provide reliable and fast internet to millions of users worldwide, including populations with little or no connectivity, rural communities, aircraft, watercraft, and places where existing services are unreliable, too expensive, or disconnected by natural disasters. We design, build, test, and operate all parts of the system, thousands of satellites and consumer antennae that allow users to connect within minutes of unboxing.

The Starlink team is seeking out the best-in-class professionals to maximize Starlink's potential for communities and businesses around the globe.

As a Mechanical Engineer on Starlink, you will spearhead state-of-the-art production processes for our printed circuit boards (PCBs). This position is responsible for the development and implementation of all equipment, facilities, tooling, and manufacturing process technologies necessary to scale production to high volumes.

You will design and implement advanced manufacturing processes and automation, owning your projects from conception and factory design through machine installation, commissioning, factory ramp, and process optimization. You will design and run large, hands-on process Design of Experiments (DOE), optimize complex mechanical and chemical process equipment, and interact regularly with senior leadership during critical design phases.

By the end of this year, the Starlink factory in Bastrop will be the largest PCB manufacturing facility, by volume, in North America.

Your work will form the backbone for millions of next generation consumer-facing devices that we ship directly to customers and businesses all over the world. From private homes, RVs, planes, or boats, this team plays an instrumental role in leveling the playing field for high-speed connectivity.

Responsibilities

• Develop, implement, and maintain new and/or improved manufacturing processes, equipment, technologies, and facilities; examples could include laser and mechanical Computer Numerical Control (CNC) drilling machines, advanced inductive lamination machines, plasma etching chambers, screen printing and inkjet printing adhesives, automation cells, copper etching and plating lines, etc.
• Analyze production processes and machinery from a first principles, physics-based approach
• Lead Design of Experiments (DOE) to establish a stable and robust process that can be handed off to production personnel; perform defect characterization and analysis to determine root cause and develop action plans to improve yields
• Develop project plans, budgets, and cost/benefit analysis for implementation of new processes or machines
• Own and perform machine activation and testing with a small team of engineers and technicians
• Solve technical and emergent issues from manufacturing (part quality, machine reliability, process instability, etc.)

Basic Qualifications

• Bachelor's degree in engineering discipline
• 3+ years of experience with fluids, mechanical, electromechanical design, and/or analysis (internship or project team experience is applicable)

Preferred Skills and Experience

• Master's degree in engineering or a related technical discipline
• 5+ years hands-on project experience with complex fluid or mechanical based production systems in a professional setting, preferably as a lead
• 5+ years of professional experience in design and analysis
• Experience with taking products from research and development into production.
• Experience with PCB manufacturing processes like metal plating, chemical etching, CNC drill equipment, lamination presses, cleanroom equipment, etc.

Additional Requirements

• Willingness to travel to other SpaceX sites and/or vendors for potentially extended periods of time including international
• Ability to lift 25 lbs. unassisted
• Lifting, standing, climbing, bending, grasping, sitting, pulling, pushing, stooping, stretching, and carrying are generally required to perform the functions of this position
• Willing to work onsite; remote work is not considered

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.