SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

PROCESS SPECIALIST, HIGH PRESSURE DIE CASTING

SpaceX is developing a low latency, broadband internet system to meet the needs of consumers across the globe. Enabled by a constellation of low Earth orbit satellites, Starlink will provide fast, reliable internet to populations with little or no connectivity, including those in rural communities and places where existing services are too expensive or unreliable. We are looking for an automation & controls specialist to help design and develop control systems and software for production line machinery to manufacture, test, and track Starlink consumer devices in a high volume manufacturing facility.

Working directly in the materials engineering group, this position will primarily support manufacturing and development of SpaceX’s Starlink product components alongside a strong group of mechanical and process engineers. The goal of the team is to develop new manufacturing methods and qualify processes to be introduced into production.  As an HPDC Process Specialist, you will be responsible for maintaining daily production uptime of fully automated casting machines, including all subsequent post-cast operations such as trimming, machining, and coating. This position also involves the proper documentation of process settings through setup sheets and maintenance of process books and their contents. Other tasks relevant to the process specialist include carrying out metallurgical analyses, developing work instructions, and training others as necessary.

RESPONSIBILITIES:

• Develop and qualify high pressure die cast processes through the means of PQ2 analysis and flow simulations
• Lead design of experiments (DOE) to establish a stable and robust process that can be handed off to production personnel
• Develop detailed training manuals and independently train production staff on machine and cell operations
• Solely responsible for establishing work instructions that will drive day to day operations in the die cast cell.
• Audit manufacturing process - assess process inefficiencies, safety improvements, and potential optimizations through the implementation of automation
• Independently design, fabricate, and integrate tooling (robotic end of arm tooling, quality check fixtures, go/no-go gauges, and other tools) that can be incorporated into the process and planning to further improve and refine the casting process.
• Determine requirements for validating product conformance as well as establishing the requirements for lot traceability and inspections as defined in the process qualification and design of experiments.
• Manage supply chain of raw materials through research of aluminum alloys, trading cost and lead time
• Independently install, maintain, and troubleshoot relay, ladder diagrams, components, photo-eyes, motor starters, limit switches, proximity sensors, solenoids, etc.
• Develop methodology and process to monitor die temperatures and automated evaluation (including acceptance criteria) for start-up procedure vs. steady-state production
• Set up die cast machine, recipe, and ladle/dosing furnace for consecutive jobs
• Create coupon mold/sample molds daily to check metal chemistry using handheld XRF spectroscopy
• Solve technical and emergent issues on the manufacturing cell (part quality, machine reliability, process instability, etc) without engineering oversight
• Monitor all process parameters and peripherals in die cast machine cell, including melt furnaces, thermal control units, die spray, and testing equipment to ensure correct operation and performance
• Create and manage die spare parts lists and ensure parts are set up and in stock prior to start of production
• Create and manage die PM system, including detailed work instructions and manage on schedule completion of PM activities

BASIC QUALIFICATIONS:

• High school diploma or equivalency certificate
• 5+ years of high pressure die casting experience in a production environment
• 3+ years of experience working with aluminum alloys in casting operations (low or high pressure)
• 2+ years troubleshooting and programming 6-axis robots in a HPDC cell

PREFERRED SKILLS AND EXPERIENCE:

• 7+ years high pressure die casting experience in a production environment
• 3+ years of experience with highly automated die casting cells
• 3+ years casting experience with Idra brand die cast machines
• 3+ years hydraulic/pneumatic and mechanical maintenance
• Experience in independently troubleshooting advanced electrical circuits, electronic systems, motors & starters, electrically operated equipment and making successful repairs and modifications
• Proficient in excel, office, and word
• Ability to interpret geometrical tolerances on part drawings
• Electrical wiring experience and some knowledge of how PLCs, sensors, and other electrical components are wired and work

ADDITIONAL REQUIREMENTS:

• Willingness to travel to other SpaceX sites and/or vendors for significant/extended periods of time (in excess of 50% of the time)
• Ability to lift up to 35 Ibs unassisted
• Standing/walking for long periods of time
• Willingness to work long hours and weekends as necessary to accommodate manufacturing and test campaigns

ITAR REQUIREMENTS:

• To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.  

SpaceX is an Equal Opportunity Employer; employment with SpaceX is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Applicants wishing to view a copy of SpaceX’s Affirmative Action Plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should notify the Human Resources Department at (310) 363-6000.