Sr. Materials Engineer, Metal Casting (Starlink)

Location: Bastrop, TX

Department: Materials Engineering - Starlink Mfg - BA

SR. MATERIALS ENGINEER, METAL CASTING (STARLINK) 

At SpaceX we’re leveraging our experience in building rockets and spacecraft to deploy Starlink, the world’s most advanced broadband internet system. Starlink is the world’s largest satellite constellation and is providing fast, reliable internet to 1M+ users worldwide. We design, build, test, and operate all parts of the system – thousands of satellites, consumer receivers that allow users to connect within minutes of unboxing, and the software that brings it all together. We’ve only begun to scratch the surface of Starlink’s potential global impact and are looking for best-in-class engineers to help maximize Starlink’s utility for communities and businesses around the globe.  

As a member of the Starlink High Pressure Die Casting Materials team at our Bastrop facility, you will own solving complex materials challenges of our Starlink designs in a rapidly innovating environment. You will regularly interface with engineering and production teams, as well as have hands-on responsibilities with hardware, ultimately ushering in the next era of connectivity and delivering internet to those who need it most. 

RESPONSIBILITIES:  

• Provide materials selection and process support for all Starlink aluminum casted components
• Develop mechanical and physical properties of metallic alloys and joints for the design community 
• Perform root cause investigations using fractography, metallography, and characterization techniques 
• Develop, qualify and troubleshoot metal casting processes used in production 
• Provide technical review and advising for design efforts as it relates to material alloy and form selection, material and process specifications, metal-joining processes, design allowables 
• Collaborate with and support vendors on qualification and property development of custom-manufactured and castings 

BASIC QUALIFICATIONS: 

• Bachelor’s degree in material science, materials engineering, weld engineering, metallurgical engineering, or other engineering discipline 
• 5+ years of experience with metal casting technologies (high pressure die casting, low pressure, sand, permanent mold) 
• 5+ years of experience in metallographic characterization techniques and equipment, such as SEM-EDS, optical microscopy, hardness testers, mechanical property testing, and/or spectroscopy techniques for composition or phase 

PREFERRED SKILLS AND EXPERIENCE: 

• Master's degree or Ph.D. in material science, materials engineering, weld engineering, metallurgical engineering, or equivalent engineering discipline 
• 8+ years of professional experience with metal-casting technologies  
• 8+ years of professional experience with aluminum alloys used for structural and non-structural applications 
• Broad understanding of metal alloys used for casted applications 
• Strong interpersonal and collaborative skills with enthusiasm for the team’s spirit of innovation in cutting-edge technology 
• Experience with technical review of material processes and a first principles understanding of how process variables impact material performance 
• Demonstrated track record of success in a rapidly growing, fast-paced and highly competitive environment 
• Personality and drive to execute in a scrappy entrepreneurial environment that operates under tight timelines and aggressive schedules 
• Hands-on experience in a high-production manufacturing environment 
• Effective written and interpersonal communication skills 

ADDITIONAL REQUIREMENTS:

• Willingness to travel to other SpaceX sites and/or vendors for significant/extended periods of time (up to 25%)
• Ability to lift up to 30 Ibs unassisted
• Standing/walking for long periods of time
• Willingness to work long hours and weekends as necessary to accommodate manufacturing and test campaigns