Materials Engineer, Metal Casting

Materials Engineer, Metal Casting at SpaceX

At SpaceX, we are driven by the belief that humanity's future lies among the stars. We are actively developing groundbreaking technologies to enable human life on Mars, and a critical part of this mission is Starlink, the world's most advanced broadband internet system. Starlink, the largest satellite constellation globally, is already delivering fast, reliable internet to over 1 million users. We meticulously design, build, test, and operate every aspect of the system, from thousands of satellites to user-friendly consumer receivers and the unifying software. We've only scratched the surface of Starlink's potential, and we are seeking exceptional engineers to help maximize its global impact for communities and businesses.

As a Materials Engineer, Metal Casting on the Starlink High Pressure Die Casting Materials team at our Bastrop facility, you will be instrumental in resolving complex materials challenges inherent in Starlink designs within a fast-paced, innovative environment. You will regularly collaborate with engineering and production teams and engage directly with hardware, contributing significantly to the next era of global connectivity.

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 utilizing fractography, metallography, and various characterization techniques.
• Develop, qualify, and troubleshoot metal casting processes used in production.
• Offer technical review and advising for design efforts concerning material alloy and form selection, material and process specifications, and metal-joining processes.
• Collaborate with and support vendors on qualification and property development of custom-manufactured components and castings.

Basic Qualifications

• Bachelor’s degree in material science, materials engineering, weld engineering, metallurgical engineering, or a related engineering discipline.
• Experience with metal casting technologies, including high-pressure die casting, low pressure, sand, or permanent mold.
• 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 analysis.

Preferred Skills And Experience

• Master's degree or Ph.D. in material science, materials engineering, weld engineering, metallurgical engineering, or an equivalent engineering discipline.
• 1+ years of professional experience with metal-casting technologies.
• 1+ years of professional experience with aluminum alloys for structural and non-structural applications.
• Broad understanding of metal alloys utilized for casted applications.
• Strong interpersonal and collaborative skills, fostering innovation within the team.
• Experience with technical review of material processes and a first principles understanding of process variables impact on material performance.
• Demonstrated success in a rapidly growing, fast-paced, and highly competitive entrepreneurial environment.
• Hands-on experience in a high-production manufacturing setting.
• Effective written and interpersonal communication skills.

Additional Requirements

• Willingness to travel to other SpaceX sites and/or vendors for significant/extended periods (up to 25%).
• Ability to lift up to 30 lbs unassisted.
• Capable of standing/walking for long periods.
• Willingness to work long hours and weekends as required to support manufacturing and test campaigns.

Key skills/competency

• Metal Casting Technologies
• Materials Characterization
• Aluminum Alloys
• High Pressure Die Casting
• Metallography
• Root Cause Analysis
• Process Qualification
• Materials Selection
• Vendor Management
• Mechanical Testing