Sr. Materials Engineer, Metals (Starship)

About the role

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 structures and components. This role primarily supports component-level hardware, including control devices and mechanisms critical to 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, with compatibility across 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 spanning all Starship vehicles. If your goal is to advance propulsion control devices, materials, and manufacturing technologies, this role offers that opportunity.

Responsibilities

• Design, develop, and deploy materials and process direction for propulsion, mechanism, and valve system designs and manufacturing
• Increase reliability of internal designs’ 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 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
• 5+ 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
• 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

• 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 such as 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 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 and complete required documentation per SpaceX specifications and external standards such as NASA, OSHA, ASTM, NACE, ASME, AWS, and ASM

Pay

Pay range for Sr. Materials Engineer: $130,000.00 - $180,000.00 per year. Your actual level and base salary will be determined based on job-related knowledge, skills, education, and experience.

Benefits

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