Sr. Materials Engineer, AI Satellites (Starmind)

About the role

SpaceX is actively developing the technologies to make a future where humanity is out exploring the stars possible, with the ultimate goal of enabling human life on Mars. The Starmind team is designing, building, and operating the orbital compute fabric of the future, and is looking for a Materials Engineer to have ownership over the entire life-cycle of the hardware that enables advanced on-orbit AI processing and data center workloads.

Responsibilities

• Rapidly develop high-reliability microelectronics packages, cooling systems, and radiator hardware for satellites.
• Own the full lifecycle of materials specification, validation, and process development— including device modeling, characterization of performance metrics, and materials failure analysis.
• Drive system trades, requirements capture, materials selection, prototyping, manufacturing, failure analysis.
• Build supply chains for build-up layers, plating chemicals, coatings, thermal interface materials, and other materials for compute and satellite manufacturing.
• Define incoming acceptance criteria for materials.
• Address materials and process challenges in advanced packaging while spearheading the development of next-generation TIM materials to improve packaging performance.
• Specify and implement in-process metrology tools for quality control.
• Design thermal test vehicles and test setups to evaluate material/electronic properties.
• Integrate simulation tools with experimental data to guide and drive targeted improvements via material or process changes.
• Work closely with engineers from adjacent disciplines to deliver tightly integrated, high-performance hardware.
• Challenge assumptions, question requirements, learn from your mistakes, and approach problems with an open mind.
• Manage compliance risks related to materials and processes, ensuring safety and environmental compliance with industry standards.
• Collaborate closely with leadership and stakeholders across all departments to integrate materials innovations into product roadmaps and ensure accountability for operations and reliability.

Qualifications

The basic qualifications for this role include a Bachelor's degree in materials science, mechanical engineering, or other engineering discipline, and 5+ years of experience in microelectronics device research or manufacturing.

Skills

• Advanced degree in materials science or similar field.
• Experience in hardware, robotics, automation, or manufacturing environments.
• Experience designing tooling, fixtures, or jigs for assembly or test applications.
• Exposure to scripting or data analysis tools (e.g., Python, MATLAB, or equivalent) for process data analysis or automation.
• Experience working with precision assemblies, robotic systems, or automated pick-and-place equipment.
• Familiarity with manufacturing process development methodologies (e.g., PFMEA, process capability studies, SPC).
• Experience with or interest in production data systems, MES, or manufacturing traceability infrastructure.
• Familiarity with cleanroom or controlled-environment manufacturing practices.

Additional Requirements

• Ability to work extended hours or weekends as needed for mission critical deadlines.
• Some travel may occasionally be required.
• To conform to U.S. Government export regulations, applicant must be a U.S. citizen or national, U.S. lawful permanent resident, 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.