Mechanical Engineer - Battery Pack, Satellites (Starlink)

United States Digital Space LLC; Redmond (WA); On-site; USD 100,000 - 165,000; Full time

Benefits offered by this job

Stock options

Medical, vision, dental

Job summary

United States Digital Space LLC is seeking a Mechanical Engineer to design and develop battery packs for Starlink satellites in Redmond, WA. You will lead pack-level design, optimizing energy density and manufacturability for long-term, reliable operation in Low Earth Orbit.

You will conduct DFMEAs, drive trades for Wh/kg, and coordinate with battery cells, production, and thermal teams to ensure on-time delivery and robust performance.

Qualifications

• Bachelor's degree in engineering or STEM field.
• Experience with CAD and FEA software packages.
• 1+ year of battery pack design, analysis, testing, or manufacturing (internships/co-ops count).

Responsibilities

• Design satellite battery packs integrating thousands of 2170 cells at high voltage.
• Perform CAD & analysis of mechanical, electrical, and thermal performance under ground to orbit.
• Drive design trades to maximize pack-level Wh/kg and minimize cost per kWh.
• Conduct DFMEAs and root-cause analyses for long-term reliability.
• Validate designs via vibration, thermal, environmental, and vacuum tests.
• Collaborate with manufacturing to develop in-house production processes for pack assembly.

Skills

CAD

FEA

Battery design

Team lead experience

Communication skills

Education

Bachelor's degree in engineering

Tools

NX

ANSYS

FEMAP

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.

MECHANICAL ENGINEER - BATTERY PACK, SATELLITES (STARLINK)

the company is looking for a Mechanical Engineer to join the Starlink Battery team, focusing on battery pack-level design and development for our next generation of satellites. You will be responsible for cell-to-pack design, maximizing energy density and manufacturability of the packs while ensuring reliable long-term operation in Low Earth Orbit.

RESPONSIBILITIES:

• Design satellite battery packs that integrate thousands of 2170-format cylindrical cells at high voltage
• Perform CAD & analysis of the mechanical, electrical, and thermal performance of packs under conditions spanning ground-side validation through on-orbit operation
• Drive design trades that maximize pack-level Wh/kg and minimize $/kWh, while ensuring manufacturability and fault tolerance across satellite life
• Conduct DFMEAs and root-cause analyses to anticipate issues and ensure long-term reliability
• Validate designs via qualification testing including vibration, thermal, environmental, & vacuum testing
• Work closely with manufacturing teams to develop efficient in-house production process for pack assembly; own the pack lifecycle from upstream component vendors through pack production
• Demonstrate extreme ownership of product outcomes at every stage of development and production; own product delivery timeline through conception, design, assembly, and launch
• Collaborate with supporting teams including battery cell, production & manufacturing, abuse testing, flight software, and thermal analysis to ensure high-reliability pack performance & operation

BASIC QUALIFICATIONS:

• Bachelor's degree in an engineering or other STEM discipline
• Experience with CAD and FEA software packages
• 1+ years of experience with battery pack design, analysis, testing, and/or manufacturing (internships, co-ops, lab work and club-team experience can apply)

PREFERRED SKILLS AND EXPERIENCE:

• 2+ 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
• Professional experience with 2170-format battery design, manufacturing, and testing
• Proficiency in CAD and analysis software (NX, ANSYS, and FEMAP preferred)
• Solid understanding and application of GD&T
• Experience executing designs from prototypes through high-volume production ramp
• Self-motivated with strong organizational, written, and oral communication skills
• Experience with design of experiments, statistical process control, and process qualification
• Experience working with PCB designers and exposure to PCB layout and PCBA mechanical design

ADDITIONAL REQUIREMENTS:

• Must be willing to work extended hours and weekends as necessary for mission critical deadlines
• Must be willing to travel as needed

COMPENSATION AND BENEFITS:

Pay Range:

Level 1: $100,000.00 - $135,000.00Level 2: $115,000.00 - $165,000.00

Your actual level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills, education, and experience.

Base salary is just one part of your total rewards package at the company. You may also be eligible for long-term incentives, in the form of company stock or long-term cash awards, as well as potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan. You will also receive access to comprehensive medical, vision, and dental coverage, access to a 401(k) retirement plan, short and long-term disability insurance, life insurance, paid parental leave, and various other discounts and perks. You may also accrue 3 weeks of paid vacation and will be eligible for 10 or more paid holidays per year. Employees in Washington State accrue paid sick time in compliance with state and federal law. Company shuttles are offered to employees for roundtrip travel from select Seattle locations to the the company Redmond office Monday to Friday.

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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