Mechanical Engineer, Insource Manufacturing (Starlink)

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

Job summary

United States Digital Space LLC seeks a Mechanical Engineer for Insource Manufacturing (Starlink). You will own manufacturing subsystems from concept to high-volume production, driving design criteria, cross-functional collaboration, and system-wide optimization.

The role emphasizes robust mechanical and automation systems, FMEA, and reliability modeling. You will design production equipment, oversee vendors, and ensure high availability through preventive/predictive maintenance, while balancing

Qualifications

• Bachelor’s degree in mechanical, manufacturing, materials, or other engineering discipline.
• 1+ years of experience with mechanical design, analysis, testing, or manufacturing (internship experience is applicable)
• 1+ years of experience with CAD and FEA software packages.
• Experience with custom machine design including electromechanical systems, end-of-arm tooling, motors, actuators, linear rails, bearings, and lifting/rigging.
• Proficient in 3D CAD (Siemens NX preferred) and Teamcenter.
• Solid understanding of GD&T, mechanical engineering fundamentals, structural analysis, and failure modes of complex mechanical systems.
• Prior ownership of a complex component or assembly from initial design through production ramp.
• Experience applying common manufacturing processes (welding, machining, assembly, inspection) and designing for manufacturability.
• Hands-on experience with mills, lathes, manual and CNC machines.
• Experience with FEA, structural hand calculations, and sizing of mechanical components.
• Self-motivated with strong organizational, written, and oral communication skills.

Responsibilities

• Own manufacturing subsystems and equipment from conceptual design through fabrication, commissioning, and high-volume production ramp.
• Develop design criteria, collaborate with cross-functional teams, and drive system-level optimization.
• Perform FMEA, reliability modeling, and stress testing to predict and mitigate failures and improve OEE.
• Design and develop production equipment including structures, mechanisms, robot end effectors, automation systems, and material handling solutions.
• Uptime optimization: monitor equipment performance metrics using data analytics; identify bottlenecks and downtime causes, implement maintenance strategies.
• Evaluate and select equipment suppliers; oversee installation, commissioning, and ongoing performance of equipment.
• Demonstrate ownership of projects through their lifecycle while balancing multiple initiatives in a fast-paced environment.
• Collaborate with design, manufacturing, and test teams to develop products and production processes in parallel.
• Solve complex, open-ended problems with speed, efficiency, and scalability.

Skills

Mechanical design

FMEA

GD&T

Data analytics

Machining

CNC

Programming logic for tooling

Education

Bachelor’s degree in mechanical, manufacturing, materials, or other engineering discipline

Tools

Siemens NX

Teamcenter

CAD

FEA software

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, INSOURCE MANUFACTURING (STARLINK)

The Insource Manufacturing teamis responsible fordesigning, building, and qualifying custom equipment and automation systems to enable high-volume production of Starlink products. As a Mechanical Engineer in this group, you will take end-to-end ownership of critical manufacturing equipment and material handling systems. This role requires a detail-oriented engineer who is passionate about designing robust mechanical and automation systems,optimizingexisting equipment, and developing novel solutions that push the boundaries of high-volume manufacturing while minimizing risk and maximizing efficiency in ourstate-of-the-artStarlink factory.

RESPONSIBILITIES:

• Own manufacturing subsystems and equipment from conceptual design through fabrication, commissioning, and high-volume production ramp
• Develop design criteria, collaborate on requirements with cross-functional teams, and drive system-level optimization
• Perform failure modes and effects analysis (FMEA), reliability modeling, and stress testing to predict and mitigate potential failures and improve overall equipment effectiveness (OEE)
• Design and develop production equipment including structures, mechanisms, robot end effectors, automation systems, and material handling solutions
• Uptime Optimization:Monitorand track equipment performance metrics using data analytics;identifybottlenecks and downtime causes, then implement preventive and predictive maintenance strategies to maximize operational availability
• Evaluate and select equipment suppliers and vendors based on reliability, performance, and business needs; oversee installation, commissioning, and ongoing performance of both internally designed and vendor-supplied equipment
• Demonstrate extreme ownership of projects through their entire lifecycle while balancing multiple initiatives in a fast-paced environment
• Collaborate closely with design, manufacturing, and test teams to develop products and production processes in parallel
• Solve complex, open-ended problems with an emphasis on speed of execution, efficiency, and scalability

BASIC QUALIFICATIONS:

• Bachelor’s degree in mechanical, manufacturing, materials, or other engineering discipline
• 1+ years of experienceprofessional experience with mechanical design, analysis, testing, or manufacturing (internship experience is applicable)
• 1+ years of experience with CAD and FEA software packages

PREFERRED SKILLS AND EXPERIENCE:

• Experience with custom machine design including electromechanical systems, end-of-arm tooling, motors, actuators, linear rails, bearings, and lifting/rigging
• Proficient in 3D CAD (Siemens NX preferred) and Teamcenter
• Solid understanding and application of GD&T, mechanical engineering fundamentals, structural analysis, and failure modes of complex mechanical systems
• Prior ownership of a complexcomponentor assembly frominitialdesign through production ramp
• Experience applying common manufacturing processes (welding, machining, assembly, inspection) and designing for manufacturability
• Hands-on experience with mills, lathes, manual and CNC machines
• Experience with FEA, structural hand calculations, and sizing of mechanical components
• Self-motivated with strong organizational, written, and oral communication skills

ADDITIONAL REQUIREMENTS:

• Willingness to travel to other the company sites and/or vendors for significant/extended periods of time (~25% travel normally, more during urgent manufacturing and test campaigns)
• Ability tolift upto 25Ibs unassisted
• Standing/walking forlong periodsof time
• Ability to work long hours and weekends as necessary to support critical milestones

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.

Applicants wishing to view a copy of the company’s Affi…