Sr. Process Engineer, Starship Materials Production

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 ofenabling human life on Mars.

PROCESS ENGINEER STARSHIP MATERIALS PRODUCTION

SpaceX continues to revolutionize the launch industry by combining advanced technological developments with pragmatic and lean manufacturing. The Dispensary (in-house glue factory) produces silicone adhesives paints ablatives and thermal protection materials that support Starship and programs across the company. As a Machinery & Automation Engineer for Starship Materials Production you will own equipment and tooling from design and procurement through vendor buyoff factory installation automation and production ramp. Scope covers powder systems industrial mixers liquid dispensing and the custom tooling that makes those cells run at rate with minimal operator-dependent variation.

RESPONSIBILITIES:

• Design specify procure install and commission powder handling/dispensing systems industrial mixers and liquid dispensing equipment for paints adhesives ablatives sealants fillers and other formulated materials
• Own powder equipment including hoppers feeders (screw vibratory loss-in-weight) weigh/batch systems dust collection pneumatic conveying and powder-to-liquid incorporation
• Own mixers and blending equipment (high-shear planetary dual-asymmetric ribbon paddle vacuum reactors) including agitation vacuum/degassing temperature control seals cleanability and integration with upstream feed and downstream dispense/packaging
• Own liquid dispensing systems including pumps meters valves manifolds tanks pressure/vacuum and temperature control and single- or multi-component meter-mix-dispense platforms
• Automate production cells with sensors motion recipe/batch control interlocks data logging and PLC/HMI/SCADA integration to maximize unattended or semi-attended operation
• Design custom tooling and fixtures that enable automation (dispense/hold tooling changeover tooling transfer tooling alignment jigs poke-yoke robot/gantry interfaces); take tooling from CAD through fabrication tryout and production release
• Lead capital equipment projects cradle-to-grave: vendor selection design reviews SOWs procurement factory acceptance testing (FAT) at vendor sites site acceptance testing (SAT) installation and ramp
• Travel to vendors to execute FATs validate rate/accuracy/repeatability/cleanability/safety and drive design corrections before shipment
• Productionize equipment and processes for new product introductions (NPIs) including work instructions control plans and rate capability demonstration
• Partner with materials quality production and design to ensure formulations are mixable and dispensable at scale and meet flight quality requirements
• Drive root cause analysis design of experiments (DOE) and statistical process control (SPC) on mix and dispense performance; continuous improvement for throughput changeover cleanability dust control and cost
• Develop and maintain process specifications SOPs and equipment documentation; train technicians and hand off reliable cells to production
• Support hazardous materials handling containment and EHS requirements for solvent-based reactive and powder chemistries

BASIC QUALIFICATIONS:

• Bachelors degree in chemical engineering mechanical engineering materials engineering manufacturing engineering or related technical discipline
• 5 years of hands-on experience with powder handling/dispensing industrial mixers liquid dispensing fluid delivery or chemical/materials production equipment

PREFERRED SKILLS AND EXPERIENCE:

• Experience designing specifying or commissioning production equipment
• Experience designing tooling or fixtures for manufacturing or automation
• Experience across powder systems mixers liquid automation/dispensing and tooling design for automation in a production environment
• Powder systems: loss-in-weight or gain-in-weight feeders hoppers pneumatic convey dust collection powder weigh/batch powder incorporation into liquids/pastes
• Mixers: high-shear planetary dual-asymmetric ribbon paddle vacuum or reactor-style; mix scale-up; vacuum degassing; temperature-controlled mixing; multi-product changeover
• Liquid automation: piston/progressive cavity/gear pumps meter-mix-dispense (MMD) pressure pots cartridge or spray systems robotic/automated dispense recipe-driven multi-component control
• Tooling design for automation using 3D CAD (SolidWorks NX Inventor or similar); GD&T and design for manufacturability
• Equipment automation experience: PLC/HMI basics sensors recipe/batch control interlocks data acquisition or defining automation requirements with controls engineers
• Full project ownership from design/procurement through FAT/SAT and production implementation including travel for vendor buyoffs
• Familiarity with silicone RTVs multi-part adhesives paints ablatives filled systems or thermal protection materials
• NPI and scale-up from lab/pilot to high-rate production; lean manufacturing and changeover reduction
• DOE SPC and statistical tools (JMP Minitab or equivalent); Six Sigma Green or Black Belt
• Hazardous materials handling chemical safety and dust control; ERP/MRP exposure

ADDITIONAL REQUIREMENTS:

• Must be able to wear and obtain certification in the wearing of an air respirator
• Must be comfortable working with solvents hazardous materials inorganic acids and bases reactive chemistries and powder materials (including dust-generating operations)
• Onsite role on the production floor; remote work not considered
• Extended hours and weekends as needed to support installs FATs production ramps and downtime recovery
• Travel for vendor FATs equipment buyoffs and related work as needed
• Ability to lift up to 25 lbs unassisted; standing climbing bending and working in production environments required
• Ability to pass required site/background checks as applicable

Your actual level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills education and experience.

Base salary is just one part of your total rewards package at SpaceX. You may also be eligible for long-term incentives in the form of company stock or long-term cash awards as well as potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan. You will also receive access to comprehensive medical vision and dental coverage access to a 401(k) retirement plan short and long-term disability insurance life insurance paid parental leave and various other discounts and perks. You may also accrue 3 weeks of paid vacation and will be eligible for 10 or more paid holidays per year. Employees accrue paid sick leave pursuant to Company policy which satisfies or exceeds the accrual carryover and use requirements of the law.

ITAR REQUIREMENTS:

• To conform to U.S. Government export regulations applicant must be a (i) U.S. citizen or national (ii) U.S. lawful permanent resident (aka green card holder) (iii) Refugee under 8 U.S.C. 1157 or (iv) Asylee under 8 U.S.C. 1158 or be 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 SpaceXs Affirmative Action Plan for veterans and individuals with disabilities or applicants requiring reasonable accommodation to the application/interview process should reach out to.