Materials Engineer, Metals (Starship)

Our Starship Materials Engineering team serves as experts in various material disciplines to the broader company, working on making the best rockets and spacecraft in the world. As a member of this team, you will constantly improve the materials and processes used to create these structures and components. This role primarily supports component-level hardware, including control devices and mechanisms that drive critical capabilities on Starship/Super Heavy—such as regulators, butterfly valves, and flap/fin actuators. We design, manufacture, and test these components for maximum reliability in extreme environments, compatibility with various fluids, temperatures ranging from 80 to 800K, and pressures beyond 800 bar. Special processing of metals—including plate/bar/sheet processing, casting, forging, coatings, and heat treating—will allow you to impact the design, analysis, and manufacturing of components across all Starship vehicles.

Responsibilities

• Design, develop, and deploy materials and process direction for propulsion, mechanism, and valve system designs and manufacturing
• Increase reliability of internal design’s manufacturing processes through material and process selection, analysis, development, and test
• Develop physical, mechanical, and thermal properties for materials
• Improve special processes and materials through characterization and development
• Work directly with component design, build, test engineering, design reliability, and production teams on a daily basis
• Perform root cause investigations using fractography, metallography, and testing
• Provide technical reviews and advising for design efforts specifically related to drawings, specifications, and material requirements
• Collaborate with other engineers, subject matter experts, and technicians to solve complex material and processing challenges on current and next-generation vehicles

Requirements

• Bachelor's degree in materials engineering or other engineering discipline with emphasis on materials
• 2+ years of professional work experience in a materials engineering related role
• Experience and expertise with multiple of the following manufacturing methods: tribological coatings (conversion, inorganic, dry-film lubricants), sheet/plate metal processing, casting, forging, brazing, welding, and heat treating
• Extended hours and weekend work may be required to support critical project and mission milestones
• Up to 10% domestic travel is expected

Preferred Skills And Experience

• Master's degree or PhD in materials engineering or related field
• Tribological processes including evaluating and implementing protective coatings (polyurethane, urethane, conversion coating, inorganic coatings, dry-film lubricants) for internal and external environmental conditions including thermal, wear, atmospheric, and space environments
• Understanding of mechanical testing methods for metals including wear, tensile, fracture, and fatigue
• Familiarity with development of design allowables
• Experience with failure analysis and fractography including characterization techniques such as Fourier-transform infrared spectroscopy (FTIR), Scanning Electron Microscopy (SEM), and metallographic analysis
• Knowledge of aerospace metals including nickel-based alloys, stainless steels, aluminum alloys, and titanium alloys
• Knowledge of fluid and gas compatibility for various launch vehicle and spacecraft propulsion and fluid systems
• Hands-on experience in a manufacturing environment
• Understanding of non-destructive test methods for fracture and fatigue control
• Maintain working knowledge of regulatory requirements, perform associated required tasks, and complete required documentation per SpaceX specifications and other external specifications such as NASA, OSHA, ASTM, NACE, ASME, AWS, ASM, etc.

Benefits

• Comprehensive medical, vision, and dental coverage
• Access to a 401(k) retirement plan
• Short and long-term disability insurance
• Life insurance
• Paid parental leave
• Various discounts and perks
• 3 weeks of paid vacation and 10 or more paid holidays per year
• Paid sick leave pursuant to company policy
• Eligibility for long-term incentives in the form of company stock or long-term cash awards
• Potential discretionary bonuses
• Ability to purchase additional stock at a discount through an Employee Stock Purchase Plan

Pay

Pay range:

• Level I: $100,000.00 - $115,000.00 per year
• Level II: $110,000.00 - $135,000.00 per year

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

To conform to U.S. Government export regulations, applicant must be a U.S. citizen or national, U.S. lawful permanent resident (green card holder), Refugee under 8 U.S.C.1157, or Asylee under 8 U.S.C.1158, or be eligible to obtain the required authorizations from the U.S. Department of State.