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.
SUPPLIER DEVELOPMENT ENGINEER, ASSEMBLY PROCESS (STARLINK)
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 talented, creative, and driven engineers to develop, drive, and maintain suppliers, from initial concept development to full scale production.
The role entails early engagement in global 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. This position demands deep manufacturing process expertise and extreme ownership from early design selection through process characterization, line qualification, and field performance feedback.
RESPONSIBILITIES:
- Own end-to-end process development, equipment bring-up, and qualification for precision assembly technologies at contract manufacturers, spanning strategic supplier selection, new product introduction (NPI), and high-volume production
- Engage early with suppliers on equipment selection, tooling design, and process engineering to properly set up high-volume manufacturing programs by ensuring material and process corners are fully characterized and completed
- Lead development of ultrasonic welding processes, including amplitude, force, energy, weld time, and trigger optimization, as well as horn design, joint geometry, and weld strength validation for both metal and thermoplastic components
- Develop hot plate welding and vibration welding processes for plastic housings and enclosures, focusing on temperature uniformity, platen design, melt displacement control, weld pressure profiles, and long-term joint durability
- Optimize heat staking and hot riveting processes for plastic boss forming, including temperature control, pressure profiling, staking tool design, and dimensional stability validation
- Develop and qualify precision dispense processes for thermal interface materials (TIM), adhesives, and sealants, including rheological characterization, volumetric vs. time-pressure dispensing, needle selection, vision-guided positioning, and repeatable bead or dot formation
- Establish and optimize automated optical inspection (AOI) systems, including multi-angle lighting techniques, high-resolution imaging, algorithm development, false call reduction, and integration with deep learning-based defect detection
- Design and execute comprehensive design of experiments (DOE) and corner case studies (material and process windows) to define robust parameter ranges and ensure process capability across environmental and material variations
- Lead line qualification activities at contract manufacturers, including equipment installation qualification (IQ), operational qualification (OQ), performance qualification (PQ), gauge repeatability and reproducibility (GR&R), and production part approval process (PPAP)
- Develop detailed process control plans, failure mode and effects analysis (FMEA), statistical process control (SPC) limits, and reaction plans to sustain high process capability in mass producti