Sr. Mechanical Engineer, Satellites - (Starlink)

Starlink is the world’s largest satellite constellation, providing broadband-quality internet anywhere on earth. We’re leveraging SpaceX knowledge in building rockets and spacecraft to deploy thousands of satellites each year; today’s constellation serves over five million customers in more than 120 countries. We design, build, test, and operate all parts of the system – the satellite hardware, the user antennas, and the software that brings it all together.

About the role

As a mechanical design engineer within the satellite vehicle engineering organization, you will solve complex structural, thermal, and electromechanical problems on space-grade hardware that powers our satellites. You will own the full design lifecycle—from ideation and design to testing, manufacturing, and large-scale production—while collaborating with cross-functional engineering teams to democratize internet access worldwide.

There are several sub-teams within the vehicle engineering group, each with a distinct focus. Applicants will be considered broadly and matched to a team based on technical fit, team needs, and candidate preference:

• Mechanisms Team: End-to-end electromechanical design for actuators, reaction wheels, torque rods, solar arrays, and more.
• Space Lasers Team: Opto-mechanical design for industry-leading space lasers and optical payloads, in partnership with the optical team.
• Bus Avionics Team: Mechanical design for avionics modules, thermal and structural components, new part selection, harnessing, and satellite integration.
• Structural Team: Design and analysis of the satellite primary structure, including chassis, ribs, rails, and propulsion tanks.
• Solar Arrays Team: Work on the world’s most prolific space solar design and factory, covering flight arrays, test/production machines, and thermal/electrical/material interfaces.
• Battery Packs Team: Mechanical design, thermal, and electrical analysis for in-house battery packs, emphasizing mass-efficient and runaway-resistant architectures.

Responsibilities

• Own hardware from conceptual design through high-volume production and on-orbit operation for the Starlink constellation.
• Develop design criteria, collaborate on requirements, and drive system-level optimization.
• Rapidly iterate on designs and analysis to inform high-level systems trades and steer product direction.
• Drive holistic Design for Manufacturing (DFM) to reduce part and process complexity, error-proof fabrication/integration, and ensure consistent performance and production metrics.
• Establish an efficient product lifecycle from supply chain to final integration, balancing cost, complexity, and quality; design and implement in-house production lines.
• Perform environmental and performance testing to validate analysis and demonstrate compliance with design criteria.
• Own product delivery timelines from conception through launch.
• Demonstrate extreme ownership of product outcomes at every stage of development and production.

Requirements

• Bachelor's degree in an engineering discipline.
• Experience with CAD and FEA software packages.
• 5+ years of professional experience in mechanical/electromechanical design, analysis, testing, and/or manufacturing.
• Ability to work long hours and weekends as necessary to support mission-critical milestones.
• To conform to U.S. Government export regulations, applicant must be a U.S. citizen or national, lawful permanent resident (green card holder), Refugee under 8 U.S.C. §1157, or Asylee under 8 U.S.C. §1158, or be eligible for required authorizations from the U.S. Department of State.

Preferred Skills and Experience

• Master’s degree in engineering or a related technical discipline.
• 3+ years of professional experience in mechanical design and analysis.
• 2+ years of hands-on project experience with complex mechanical systems, preferably as a team lead.
• Proficiency in 3D CAD (NX preferred).
• Solid understanding and application of GD&T.
• Demonstrated expertise in structural analysis and failure modes of complex mechanical systems.
• Prior ownership of a complex component or assembly from initial design through high-volume production.
• Self-motivated with strong organizational, written, and oral communication skills.
• Team-specific skills may include:
  • Knowledge of material selection, manufacturing methods, and surface treatments for mechanical components.
  • Proficiency in one or more programming languages.
  • Experience working with PCB designers and exposure to PCB layout and PCBA mechanical design.
  • Experience with design of experiments, statistical process control, and process qualification.
  • Expertise applicable to any of the sub-teams listed above.

Pay

Pay range: $130,000 – $180,000 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 discounts.
• Long-term incentives, including company stock, stock options, or long-term cash awards.
• Potential discretionary bonuses.
• 3 weeks of paid vacation and 10+ paid holidays per year (Washington State employees accrue paid sick time).
• Company shuttles for roundtrip travel from select Seattle locations to the SpaceX Redmond office (Monday to Friday).