Sr. Supplier Development Engineer, Mechanical Metrology (Starlink)

About the role

Starlink User Terminal business is experiencing exponential growth across consumer, retail, enterprise, and mobility applications. This rapid expansion requires a highly resilient and scalable supply chain with world-class precision measurement capabilities for high-tolerance mechanical components.

The role entails early engagement in supplier selection, equipment selection, and process engineering to set programs up for success in high-volume manufacturing by ensuring material and process corners are fully completed. The role also includes ownership to deliver on time, monitor field performance, react to issues, and feed lessons learned back to engineering teams for iterative improvement.

We are seeking a Metrology Engineer with strong technical and leadership skills to drive supplier development, metrology strategy, and AI-enabled measurement systems for mechanical parts in high-volume production. The Supplier Development Engineer, Mechanical Metrology will be responsible for executing end-to-end supplier strategies focused on precision mechanical components and their associated metrology processes. This position will have significant technical and leadership influence across Starlink engineering, quality, and supply chain teams.

Responsibilities

• Own end-to-end supplier development for mechanical metrology and high-precision mechanical components within the Starlink User Terminal Bill of Materials, spanning strategic supplier selection, new product introduction (NPI), qualification, production ramp, and reactive quality support
• Engage early with suppliers on selection, equipment selection, and process engineering to properly set up high-volume manufacturing programs by ensuring material and process corners are fully characterized and completed
• Provide technical guidance on mechanical metrology methods, Geometric Dimensioning and Tolerancing (GD&T) implementation, datum scheme development and best practices, PC-DMIS programming, surface texture and surface technology standards, and measurement system analysis (MSA) while driving adoption of AI-powered metrology solutions
• Design, develop, and qualify precision measurement fixtures, including fixture concept design, datum scheme optimization, repeatability studies, and qualification to ensure measurement system stability and accuracy
• Assess supplier manufacturing and metrology capabilities, including capacity, process windows, gage repeatability and reproducibility (GR&R) performance, uncertainty budgets, datum scheme robustness, and scalability for high-volume production of tight-tolerance mechanical parts
• Indirectly manage internal metrology lab activities and technicians by setting technical direction, prioritizing work, and ensuring consistent execution of measurement standards and best practices
• Implement artificial intelligence (AI) and machine learning solutions for metrology, including automated vision inspection, predictive analytics on measurement trends, anomaly detection, and intelligent data interpretation systems
• Lead Production Part Approval Process (PPAP), First Article Inspections (FAI), gage repeatability and reproducibility (GR&R) studies, and production rate ramps to enable full-rate, high-volume manufacturing
• Develop and execute robust qualification plans including dimensional validation, surface finish and texture analysis, coordinate measuring machine (CMM) and optical measurement correlation, and environmental stability testing
• Drive supplier performance improvement through Lean methodologies, supplier scorecards, process audits, and systematic problem solving to deliver measurable gains in quality, cost, and delivery
• Perform reactive quality engineering support, including rapid containment, root cause analysis, and corrective actions for measurement escapes, dimensional non-conformances, and field issues
• Own on-time delivery of qualification and production ramp activities while continuously monitoring field performance, reacting quickly to issues, and feeding lessons learned from field data back to design and process engineering teams for iterative improvement
• Ensure internal customers are highly satisfied by delivering not only precise measurement data but clear engineering inferences, trend analysis, and actionable recommendations derived from metrology results

Basic Qualifications

• Bachelor's degree in mechanical engineering, metrology, industrial engineering, or a other engineering discipline
• 6+ years of experience in mechanical metrology, precision manufacturing, or supplier development (internship and extracurricular experience is applicable)

Preferred Skills and Experiences

• 10+ years of experience in mechanical metrology, precision manufacturing, or supplier development
• Strong technical background in Geometric Dimensioning and Tolerancing (GD&T), dimensional metrology, measurement system analysis, and high-volume production environments
• Demonstrated leadership skills with experience indirectly managing labs, technicians, or cross-functional technical teams
• Hands-on experience implementing artificial intelligence (AI) and machine learning for metrology applications
• Proficiency in PC-DMIS programming for coordinate measuring machines (CMM) and strong familiarity with Hexagon CMM and Optical Measurement Machine (OMM) hardware
• Strong expertise in datum scheme development, GD&T best practices, measurement fixture design, and fixture qualification processes
• Deep knowledge of mechanical metrology tools and methods including CMMs, optical scanners, surface profilometers, laser trackers, and automated inspection systems
• Experience with Production Part Approval Process (PPAP), Advanced Product Quality Planning (APQP), Design Failure Mode and Effects Analysis (DFMEA), Process Failure Mode and Effects Analysis (PFMEA), Measurement System Analysis (MSA), and Gage R&R specifically for precision mechanical components
• Strong understanding of manufacturing capability and metrology capability assessments, including process window validation, uncertainty analysis, and process capability indices (Cp/Cpk)
• Proven ability to translate raw metrology data into meaningful engineering insights and inferences that drive design and process decisions
• Familiarity with relevant standards including ASME Y14.5 (GD&T), ISO 4287 / ISO 4288 (surface texture), ASME B46.1 (surface technology), ISO 17025, AS9100, and IPC standards
• Strong problem-solving skills using structured root cause analysis methods and statistical tools such as Minitab, design of experiments (DOE), and Six Sigma
• Excellent written and verbal communication skills with the ability to distill complex technical topics and data inferences into clear one-pagers, dashboards, and executive presentations

Additional Requirements

• Position is based in Bastrop, TX and requires being onsite - remote work not considered
• Ability to travel up to 25% of the time, both domestically and internationally
• Position may require extended working hours and occasional weekends to support production ramps and critical issue resolution
• Valid driver's license

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.