Materials Engineer, Metals (Starlink)

United States Digital Space LLC; Redmond (WA); On-site; USD 90,000 - 130,000; Full time

Job summary

United States Digital Space LLC in Redmond, WA seeks a Materials Engineer, Metals for Starlink. You will develop, qualify, and troubleshoot metallic materials and joining processes for satellites and ground hardware, supporting high-volume production and quality objectives.

Responsibilities cover materials selection, property development, failure analysis, and collaboration with suppliers and design teams to ensure manufacturability and performance in space environments.

Qualifications

• Bachelors degree in materials-focused engineering required.
• Experience with aluminum alloys used for structural/non-structural applications; metal alloys used in electronics; and metal-joining processes.

Responsibilities

• Material selection, characterization, qualification, and manufacturing support for metallic hardware on Starlink satellites and ground assemblies.
• Develop mechanical and physical properties of metallic alloys and joints for design teams.
• Perform root cause investigations and failure analysis using fractography, metallography, SEM-EDS, optical microscopy, and other testing.
• Develop, qualify, troubleshoot, and optimize metal joining processes (welding, brazing, soldering, sintering).
• Provide technical review and advising for material alloy selection, specifications, fracture requirements, and manufacturability.
• Collaborate with suppliers on qualification, property development, and issue resolution for forgings, castings, and other metallic components.

Skills

Materials science

Welding engineering

Metallurgical knowledge

Failure analysis

Characterization

Team collaboration

Education

Bachelor's degree in Materials Science/Engineering

Master's or PhD preferred

Tools

SEM-EDS

Optical microscopy

Hardness testing

Mechanical-property testing

Spectroscopy

Job description

the company 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 the company is actively developing the technologies to make this possible, with the ultimate goal ofenabling human life on Mars.

MATERIALS ENGINEER, METALS (STARLINK)

At the company, we’re leveraging our rocket and spacecraft expertise to deploy Starlink, the world’s largest and most advanced satellite constellation, delivering fast internet to over10million users worldwide. We design, build, test, and operate the full system — from thousands of satellites to user terminals and software.

We’re revolutionizing the launch market through rapid reusability and cutting-edge technology. As a Materials Engineer, you’ll take a hands-on role in developing, implementing, and troubleshooting advanced material systems. You’ll use your expertise, experience, and creativity to solve complex material selection and processing challenges as we scale Starlink for high-volume production.

RESPONSIBILITIES:

• Provide materials selection, characterization, qualification, and manufacturing process support for metallic and metal-joined (welded, brazed, soldered) hardware on Starlink satellites and ground infrastructure assemblies.
• Develop mechanical and physical properties of metallic alloys and joints for the design community, including data, allowable, and process recommendations.
• Perform root cause investigations and failure analysis using fractography, metallography, SEM-EDS, optical microscopy, and other characterization testing.
• Develop, qualify, troubleshoot, and optimize metal joining processes (welding, brazing, soldering, sintering) used in production, including understanding of process variables and resulting material performance.
• Provide technical review and advising for design efforts as it relates to material alloy selection, material & process specifications, fracture requirements, and design-for-manufacturability.
• Collaborate with suppliers on qualification, property development, and issue resolution for custom-manufactured forgings, castings, and other metallic components.

BASIC QUALIFICATIONS:

• Bachelor’s degree in Materials Science, Materials Engineering, Welding Engineering, Metallurgical Engineering or another materials-focused engineering degree
• Experience with aluminum alloys used for structural and non-structural applications; metal alloys used in electronic applications; and metal-joining processes (welding, brazing, soldering, sintering).

PREFERRED SKILLS AND EXPERIENCE:

• Master's or PhD in Materials Science, Materials Engineering, Welding Engineering, Metallurgical Engineering, or other related engineering discipline.
• Experience with characterization techniques and equipment, including SEM-EDS, optical microscopy, hardness testers, mechanical property testing, and spectroscopy techniques for composition or phase.
• Strong interpersonal and collaborative skills with enthusiasm for the team’s spirit of innovation in cutting-edge technology.
• First-principles understanding of welding processes, weld strength testing methodologies, and standards used to make informed welding decisions.
• Hands-on experience with metal-joining technologies (welding, brazing, soldering, sintering) in a high-production manufacturing environment.
• Experience with failure analysis, materials testing labs, ASTM/NASA/AMSspecs, or supplier management.
• Exper