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.

SR. PROCESS ENGINEER, 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.

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, commission equipment and qualify processes to be introduced into production.  

RESPONSIBILITIES:

• Research, design processes and implement automation technology and integration approaches to support SpaceX’s in-house aluminum die casting facility
• Install, assemble and test presses, fixtures, gaging, robotic grippers and special machines while driving process improvements, cost reduction activities and continuous improvement activities
• Lead process development of the die cast process through parameter optimization, DOE experiments, and trials that will lead to a robust process
• Develop and qualify high pressure die cast processes through the means of PQ2 analysis and flow simulations
• Lead and refine the DFM process (manufacturing, assembly, supply chain, cost, serviceability, sustainability, reliability, safety, etc.) and work closely with product design engineering teams to ensure that critical changes are incorporated in a timely manner
• Lead the subassembly and system level manufacturing line processes, oversee the design and assembly of tools, fixtures and automated assembly equipment or approve all manufacturing-related aluminum casting and new assembly integration procedures
• Oversee operator instructions, critical parameters, checklists and training materials for all casting operations, update special equipment service manuals including BOMs, drawings, wiring schematics, recommended needed processes, technical expertise, and tooling for optimization of production runs
• Diagnose equipment failures, collect data to identify root causes and develop sustainable solutions

BASIC QUALIFICATIONS:

• Bachelor’s degree in mechanical engineering, materials engineering or other technical discipline
• 5+ years of professional experience in high-pressure aluminum die casting process design, manufacturing engineering, equipment commissioning, robot programming and/or control systems design

PREFERRED SKILLS AND EXPERIENCE:

• Master’s degree or PhD in materials engineering or mechanical engineering
• 7+ years high pressure die casting experience in a production environment
• Exceptional understanding of the interactions between the high pressure die casting process conditions (e.g. die temperature, die & tip lube application, shot profile, etc.)
• Experience developing manufacturing processes for new and unique products
• Experience transitioning products from prototype to production
• Experience defining and assessing quality standards associated with common manufacturing processes including drawing specifications, limit samples, and incoming/outgoing quality control points with a proven track-record of shepherding products from tool release to mass production
• Experience with manufacturing process like injection molding, CNC, die casting, stamping, assembly, and box build in a production setting and a good understanding of the costs and schedule and complexity associated with each process

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 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

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.