Sr. Automation and Controls Engineer, Satellites (Starlink)

About the role

As a senior member of the Starlink Tooling and Automation team, you will lead creative, multi-disciplinary projects spanning machine design, robotics, motion systems, and factory health monitoring. These projects come together to form the innovative, high-rate factories that allow us to deliver internet to those that need it most. You will work with elite engineers on high-impact applications to create the factory of the future for high-volume satellite production.

Responsibilities

• Design, develop, and manage automation projects—from initial factory ideation, machine commissioning, and proof of rate capability, to eventual hand-off to operational teams.
• Architect, write, and debug PLC code with an emphasis on generating code that is organized, structured, documented, maintainable, and reusable for high-volume manufacturing applications.
• Implement ANSI/RIA15.06/OSHA compliant systems for robots, gantries, conveyors, and other manufacturing equipment to ensure factory safety and reliability.
• Generate aesthetically simple HMI screens to make complex machines easy to understand, operate, and troubleshoot.
• Design electrical systems compliant to NEC, NFPA, & UL508A regulations.
• Create schedules and budgets, and motivate the team to achieve them.

Requirements

• Bachelor's degree in an engineering, physics, or computer science discipline.
• 5+ years of total experience in industrial or factory automation design and implementation OR 5+ years of experience designing and building electro-mechanical/robotic/automated systems or products.
• Ability to work long hours and weekends as necessary to support critical milestones.
• 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.

Preferred Skills and Experience

• Excited by a quick and iterative design and manufacturing role.
• Proven ability to solve complex problems with simple solutions in both design and implementation stages.
• Excellent communication skills both written and verbal, with the ability to make plans and directional recommendations collaboratively and cross-functionally.
• Ability to engineer creative, new approaches to problems while adhering to ANSI/RIA15.06/OSHA safety requirements.
• Experience with at least one of the following disciplines (ideal candidate is interested in learning fundamentals of other areas):
• Mechanical:
  • Machine design with focus on speed, reliability, maintainability, and safety.
  • Motion system sizing and implementation (gantries, robotics, conveyance, motors, actuators, pneumatics/hydraulics, sensor selection and integration, etc.).
  • Fundamental structures hand calculations and ability to design for strength and stiffness.
  • CAD and product lifecycle management programs to generate detailed designs and drawing packages utilizing geometric dimensioning and tolerancing (Siemens NX and Teamcenter preferred).
  • Familiarity with manufacturing processes and how to design for manufacturability.
  • Exposure to production machinery, industrial sensors, and equipment (motion systems, dispense systems, temperature controllers, laser distance sensors, injection molders, die casters, etc.).
• Electrical:
  • Electrical sizing of motors, cables, circuit protection, VFD’s, motor starters, and other motion systems.
  • Design of fail-safe electrical circuits using both safety logic controllers and safety-rated relays.
  • Hands-on experience troubleshooting industrial electrical systems using tools like multimeters, oscilloscopes, EMI probes.
  • Proficiency in understanding and creating electrical schematics and single line diagrams (EPLAN preferred).
  • Field bus networks, serial communication, and Ethernet communication.
  • Hands-on experience designing and commissioning high-quality electrical panels and electro-mechanical systems with appropriate safety considerations.
  • Knowledge of NEC, NFPA, UL508A codes with ability to ensure compliance with control system safety standards.
• Industrial Software:
  • PLC programming, preferably Beckhoff TwinCAT structured text programming.
  • Programming and implementing machine safety software through the use of safety PLC’s.
  • HMI, SCADA, IoT (MQTT, OPC-UA), Ignition systems with focus on user-friendly navigation and machine health monitoring and control.
  • Field Bus Networking protocols, preferably EtherCAT, Profinet, Profisafe, Ethernet/IP.
  • Robotics programming, preferably ABB.
  • Industrial software application to mechanical assemblies, electrical systems, sensors, pneumatics/hydraulics, including how to safely checkout these interdisciplinary systems prior to production implementation.

Pay

Pay Range: Level 3: $135,000.00 - $220,000.00. 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.

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 eligibility for 10 or more paid holidays per year.
• Paid sick time for employees in Washington State in compliance with state and federal law.
• Company shuttles for roundtrip travel from select Seattle locations to the SpaceX Redmond office Monday to Friday.
• Long-term incentives in the form of company stock or long-term cash awards.
• Potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan.