Materials Engineer, Additive Manufacturing

SPACE EXPLORATION TECHNOLOGIES CORP; Hawthorne (CA); On-site; USD 100,000 - 140,000; Full time

Job summary

SpaceX Hawthorne, CA is seeking a Materials Engineer specialized in Additive Manufacturing to lead LPBF development for nickel-based superalloys for next‑gen rocket engines. You will own process development, parameter optimization, and material characterization while collaborating daily with design and manufacturing teams.

The role emphasizes hands-on LPBF expertise, post‑processing, and metallurgical testing to push capabilities in propulsion materials for SpaceX engines.

Qualifications

• Bachelor's degree in materials engineering or related field with emphasis on materials.
• 1+ years of experience developing or qualifying LPBF processes for nickel-based superalloys (e.g., Inconel 718, 625)
• Master's or PhD preferred with 3+ years of LPBF experience in nickel-based superalloys
• Hands-on LPBF parameter development, build optimization, post-processing experience (HIP, heat treatment)
• Experience with metallurgical characterization and mechanical testing of additively manufactured nickel alloys
• Experience with LPBF processes, DED, casting, forging, and heat treating
• Knowledge of fracture mechanics, fatigue, and creep testing of additively manufactured superalloys
• Hands-on experience with non-destructive testing for fracture control
• Knowledge of aerospace nickel-based alloys, stainless steels, aluminum, titanium alloys
• Experience with design allowables or material specifications for LPBF nickel alloys

Responsibilities

• Provide materials and process support for propulsion designs and manufacturing.
• Increase reliability through material and process development.
• Characterize materials physical, mechanical, and thermal properties.
• Improve additive processes with LPBF nickel-based superalloys.
• Collaborate with additive engineering and manufacturing teams daily.
• Conduct root cause investigations using fractography and metallography.
• Provide technical reviews for drawings, specs, and material requirements.
• Collaborate with engineers to solve materials and processing challenges on current and future vehicles

Skills

LPBF

Nickel-based alloys

Metallurgical characterization

Mechanical testing

Fractography

Process development

Post-processing

Design allowables

NDT

Education

Bachelor's degree in materials engineering

Master's or PhD preferred

Tools

SEM

Metallography

HIP & heat treatment equipment

Job description

Materials Engineer, Additive Manufacturing

Location: Hawthorne, CA

SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

Materials Engineer, Additive Manufacturing

Our Propulsion Materials team is responsible for developing and qualifying laser powder bed fusion (LPBF) processes for nickel-based superalloys used in next‑generation rocket engines. In this role you will own process development, parameter optimization, and material characterization for high‑performance components on Raptor engines. You will work daily with design and manufacturing teams to push the limits of what is possible with LPBF nickel superalloys and other materials. If you have significant hands‑on experience developing and qualifying LPBF processes for nickel‑based superalloys and want to apply that expertise to the most demanding propulsion applications, this is the role for you.

Responsibilities

• Provide materials and process support for propulsion system designs and manufacturing
• Increase reliability of internal designs and manufacturing processes through material and process development
• Develop physical, mechanical, and thermal properties for materials
• Improve our additive processes and materials through characterization and development, with a primary focus on laser powder bed fusion of nickel-based superalloys
• Work directly with our additive engineering and manufacturing teams daily
• Perform root cause investigations using fractography, metallography, and testing
• Provide technical reviews and advice 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 our current and next-generation vehicles

Basic Qualifications

• Bachelor’s degree in materials engineering or another engineering discipline with emphasis on materials
• 1+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)

Preferred Skills and Experience

• Master’s degree or PhD in materials engineering or related field
• 3+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)
• Direct experience with LPBF parameter development, build optimization, and post-processing (HIP, heat treatment, surface finishing)
• Experience with metallurgical characterization and mechanical testing of additively manufactured nickel alloys
• Experience with one or more of the following manufacturing methods: additive (laser powder bed fusion), direct energy deposition (DED), casting, forging, brazing, heat treating
• Understanding of mechanical testing methods for metals including fracture and fatigue
• Familiarity with standard testing methods for materials and development of design allowable
• Experience with failure analysis and fractography including techniques such as SEM and metallographic analysis
• Knowledge of aerospace metals including nickel-based alloys, stainless steels, aluminum alloys, and titanium alloys
• Hands‑on experience in a manufacturing environment
• Understanding of non‑destructive test methods for fracture control
• Proven track record developing design allowables or material specifications for LPBF nickel alloys
• Experience with fracture mechanics, fatigue, and creep testing of additively manufactured superalloys
• Hands‑on experience with process monitoring, in‑situ sensors, or advanced process control for LPBF

Additional Requirements

• Extended hours and weekend work may be required to support critical project and mission milestones
• Up to 10% domestic travel is expected

Compensation and Benefits

Pay Range:

• Level 1: $100,000.00 – $117,500.00
• Level 2: $115,000.00 – $140,000.00

Base salary is determined on a case-by-case basis and may vary based on job‑related knowledge and skills, education, and experience.

Base salary is just one part of your total rewards package. You may also be eligible for long‑term incentives, in the form of company stock or long‑term cash awards, as well as discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan. You will also receive comprehensive medical, vision, and dental coverage, a 401(k) retirement plan, short- and long-term disability insurance, life insurance, paid parental leave, and various other discounts and perks. Employees accrue 3 weeks of paid vacation and are eligible for 10 or more paid holidays per year. Paid sick leave is accrued pursuant to company policy which satisfies or exceeds the law.

EEO Statement

SpaceX is an Equal Opportunity Employer; employment with SpaceX is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Applicants wishing to view a copy of SpaceX’s affirmative action plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to [e-mail].