Mechanical Failure Analysis Engineer - Vacuum Amplifiers

Frontdoor Defense; Redmond (WA); Hybrid; USD 100,000 - 165,000; Full time

Job summary

SpaceX is seeking a Mechanical Hardware Test Engineer for the Starlink program in Redmond, Washington. You will lead failure analysis on high voltage vacuum amplifiers, perform SEM/FIB/EDS analyses, and work with design, manufacturing, and supply chain teams to improve reliability.

You will apply physics-of-failure concepts, develop new analysis techniques, monitor yield and quality metrics, and contribute to process improvements in manufacturing and testing environments.

Qualifications

• Bachelor's degree in STEM fields as listed.
• 1+ years in hardware development, failure analysis, or reliability engineering.
• Strong problem solving and technical writing skills.
• Experience with electronics, mechanical design/analysis, and RF knowledge.

Responsibilities

• Perform detailed failure analysis of novel high voltage vacuum amplifiers on new-production and active-service units.
• Perform advanced physical failure analysis using SEM, FIB, EDS, cross-sectioning, and related techniques to identify failure mechanisms in functional materials.
• Collaborate with design, manufacturing, and supply chain teams to improve product reliability and manufacturing processes.
• Apply physics-of-failure principles and develop deep knowledge of vacuum tube failure modes to determine root causes.
• Develop and improve failure analysis techniques and workflows to support new manufacturing technologies and advanced materials.
• Monitor yield rates and quality metrics, driving corrective actions to address non-conforming products.
• Drive continual improvements to designs by building physical and digital tools to analyze data collected both in the field and in the lab.

Skills

Problem solving

Written communication

Python

AI

RF principles

Education

B.Sc. in materials science

B.Sc. in mechanical engineering

B.Sc. in electrical engineering

B.Sc. in physics

B.Sc. in chemical engineering

Tools

SEM

FIB

EDS

Cross-sectioning

Fault isolation

Job description

SpaceX is seeking a Mechanical Hardware Test Engineer for the Starlink program in Redmond, Washington. You will lead failure analysis on high voltage vacuum amplifiers, perform SEM/FIB/EDS analyses, and work with design, manufacturing, and supply chain teams to improve reliability.

You will apply physics-of-failure concepts, develop new analysis techniques, monitor yield and quality metrics, and contribute to process improvements in manufacturing and testing environments.