Materials Engineer, Solar Cell Characterization

United States Digital Space LLC; Bastrop (TX); On-site; USD 85,000 - 110,000; Full time

Job summary

Starlink is hiring a Materials Engineer for solar cell characterization to lead offline metrology, build measurement capability, and interpret data to improve cell performance and yield.

You will work with process, production, and quality teams, design experiments, qualify tools, and develop robust SOPs while maintaining safety and data integrity in a high-volume manufacturing setting. Travel up to 25% may be required.

Qualifications

• Bachelors in materials science/engineering or related field.
• 1+ year in materials characterization, failure analysis, or PV metrology.
• Experience with laboratory or manufacturing environments.

Responsibilities

• Own characterization and metrology strategy for insourced solar cells.
• Develop offline electrical, optical, and materials techniques to quantify performance and yield.
• Lead root cause analysis and drive corrective actions from first principles.
• Define measurement requirements, sampling, and acceptance criteria with partners.
• Stand up metrology processes and maintain data integrity.
• Translate results into material/process improvements.
• Collaborate on DOEs and fast feedback during tool changes.
• Document methods and communicate risks and status to leadership.
• Maintain safety and quality across lab and production activities.

Skills

Materials characterization

Failure analysis

Semiconductor metrology

PV metrology

Data analysis

DOE / root cause analysis

First-principles problem solving

Communication

Leadership

Education

Bachelor's degree in materials science/engineering or related

Master's degree or PhD in related field

Tools

SEM-EDS

FIB

AFM

XRD

FTIR

XPS

SIMS

ICP-MS

Ellipsometry

Four-point probe

Optical microscopy

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, SOLAR CELL CHARACTERIZATION

Starlink is building the world's largest satellite constellation to deliver fast, reliable internet to people who need it most—and powering that constellation starts on the factory floor. We are insourcing solar cell manufacturing end-to-end, from crystal growth and ingot production through wafering and cell fabrication, to drive performance, cost, and scale at every step. High-efficiency, high-reliability cells made in-house are the backbone of the Starlink network: more photons in means more data out to customers around the world.

As a Materials Engineer for solar cell characterization, you will own offline metrology and materials characterization of insourced solar cells—building the measurement capability, analysis methods, and physical understanding needed to raise cell performance and yield. You will turn electrical, optical, and materials data into root cause, and interface with process, production, and quality teams to lock in durable fixes. If you are passionate about solving hard problems, anchor your engineering judgment with first-principles thinking, and are relentless about acting with urgency, this role is for you.

RESPONSIBILITIES:

• Own characterization and metrology strategy for insourced solar cells across cell interfaces—from method development and tool qualification through production-ready measurement recipes

• Build and maintain a suite of offline electrical, optical, and materials characterization techniques to quantify cell performance, reliability, and yield-limiting defects (e.g., I-V, quantum efficiency, PL/EL imaging, lifetime, SEM-EDS, optical microscopy, spectroscopy, and related methods)

• Lead root cause analysis for performance and yield excursions: design experiments, execute failure analysis, correlate process history with metrology signatures, and drive corrective actions to first principles

• Define measurement requirements, sampling plans, gauge R&R, calibration, and acceptance criteria in partnership with process, quality, and production engineering

• Stand up and develop processes for offline metrology equipment; own data integrity, tool matching, and measurement uncertainty so results can be trusted for process decisions

• Translate characterization results into clear material and process recommendations that improve efficiency, reliability, cost, and manufacturability

• Partner with process engineering on DOEs and golden-line development; provide rapid feedback loops during recipe, materials, and equipment changes

• Document methods, specifications, FA reports, and best practices; communicate status, risks, and recommendations clearly to cross-functional partners and leadership

• Champion a culture of safety and quality in all sample preparation, chemical handling, lab operations, and production support activities

BASIC QUALIFICATIONS:

• Bachelor's degree in materials science, materials engineering, chemical engineering, or a related technical discipline

• 1+ years of professional experience in materials characterization, failure analysis, semiconductor/PV metrology, or a related laboratory or manufacturing role (internship and co-op experience applicable)

PREFERRED SKILLS AND EXPERIENCE:

• Master's degree or PhD in materials science, materials engineering, chemical engineering, or a related technical discipline

• Hands-on experience characterizing photovoltaic devices, silicon wafers, thin films, or semiconductor devices

• Proficiency with solar cell and wafer metrology such as I-V, Suns-Voc, EQE/IQE, photoluminescence, electroluminescence, minority-carrier lifetime (QSSPC/PL), ellipsometry, four-point probe, and optical inspection

• Experience with materials analysis techniques including SEM-EDS, FIB cross-sectioning, AFM, XRD, FTIR, XPS, SIMS, ICP-MS, and optical microscopy

• Experience designing and implementing a laboratory inventory management system (including architecture, workflows, and user access), building automated pipelines to transfer metrology data from tools into the LIMS, and integrating SPC (control charts, dashboards, and alerts) on the collected data

• Demonstrated ability to lead structured root cause analysis (e.g., DOE, 5-why, fishbone, fault-tree) and convert findings into process or material improvements

• Experience qualifying metrology tools, writing measurement SOPs, and establishing statistical process controls or gauge capabilities

• Experience working in a high-volume manufacturing or fab environment and partnering with process, quality, and production teams

• Strong first-principles problem solving and a demonstrated ability to dig deep on ambiguous materials and device-performance challenges

• Comfortable with data analysis (Python, JMP, MATLAB, or equivalent) to correlate metrology, process, and electrical results

• Passion for building, learning quickly, and owning outcomes end-to-end; thrives in a fast-paced environment with tight timelines

• Effective written and verbal communication skills; able to convey technical concepts across all levels of the organization

• Self-motivated with strong organizational skills and a bias toward action

ADDITIONAL REQUIREMENTS:

• Willingness to travel to other the company sites and/or vendors as needed (up to 25%)

• Ability to lift up to 25 lbs unassisted

• Ability to stand/walk for extended periods in the lab and on the manufacturing floor

• Willingness to work extended hours and weekends as needed to support manufacturing, tool bring-up, and critical milestones

• Must be able to wear appropriate PPE for lab and manufacturing environments

ITAR REQUIREMENTS:

• 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. Learn more about the ITAR here.

the company is an Equal Opportunity Employer; employment with the company 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.

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