Materials Engineer, Metals (Starlink)

Key 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, allowable, 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.

Requirements & Tech Stack

• Bachelor’s degree in Materials Science, Materials Engineering, Welding Engineering, Metallurgical Engineering or another materials-focused engineering degree.
• 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 Materials Science, Materials Engineering, Welding Engineering, Metallurgical Engineering, or other related 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.

Compensation and Benefits

• Pay Range:
• Level 1: $100,000.00 - $135,000.00
• Level 2: $115,000.00 - $165,000.00
• Base salary determined on a case-by-case basis based on job-related knowledge and skills, education, and experience.
• Total rewards package includes potential eligibility for long-term incentives (company stock, long-term cash awards), discretionary bonuses, and Employee Stock Purchase Plan.
• Comprehensive medical, vision, and dental coverage.
• Access to a 401(k) retirement plan.
• Short and long-term disability insurance, life insurance.
• Paid parental leave.
• Various other discounts and perks.
• Accrue 3 weeks of paid vacation.
• 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 offered from select Seattle locations to the SpaceX Redmond office Monday to Friday.

ITAR Requirements

• 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.