Mechanical Hardware Test Engineer - Failure Analysis (Starlink)

InvestedintheMission; Redmond (WA); On-site; USD 100,000 - 165,000; Full time

Benefits offered by this job

Stock options

Long-term incentives

Discretionary bonuses

Employee Stock Purchase Plan

Medical coverage

Dental coverage

Vision coverage

401(k)

Disability insurance

Life insurance

Parental leave

Paid vacation

Paid holidays

Shuttle service to Redmond

Job summary

SpaceX is seeking a Mechanical Hardware Test Engineer – Failure Analysis for the Starlink program. You will solve high-impact problems by performing detailed failure analysis on vacuum amplifier hardware in both new-production and active-service units.

You will apply advanced techniques (SEM, FIB, EDS) to uncover failure mechanisms, collaborate with design, manufacturing, and supply chain to improve reliability, and develop robust workflows for next‑gen technologies.

Qualifications

• Bachelor’s degree in STEM fields.
• 1+ years of hardware development or reliability engineering experience.
• Masters degree preferred.
• Experience with SEM, FIB, EDS or related techniques.
• Strong problem-solving, communication and technical writing skills.

Responsibilities

• Perform detailed failure analysis of high voltage vacuum amplifiers in new-production and active-service units.
• Conduct advanced physical failure analysis using SEM, FIB, EDS and cross-sectioning to identify failure mechanisms.
• Collaborate with design, manufacturing, and supply chain to improve reliability and processes.
• Apply physics-of-failure principles to determine root causes of failures.
• Develop and refine failure analysis techniques and workflows for new technologies.
• Monitor yield rates and drive corrective actions for non-conforming products.

Skills

Problem solving

Communication

Hardware knowledge

RF principles

Python

AI

Education

Bachelor's degree in STEM

Master's degree

Tools

SEM

FIB

EDS

Cross-sectioning

Fault isolation

Job description

SpaceX 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 SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

MECHANICAL HARDWARE TEST ENGINEER – FAILURE ANALYSIS (STARLINK)

As a Mechanical Hardware Test Engineer, you will solve challenging, high impact problems for the Starlink network. We are producing complex vacuum amplifier hardware at orders of magnitude higher rate than anyone in history and this role will play a critical part in making it highly reliable. This requires extreme critical thinking skills and a desire to learn about nuanced, cutting edge technology. The most important skillset is demonstrated problem solving ability – in whatever form that may be.

RESPONSIBILITIES:

• Perform detailed failure analysis of novel high voltage vacuum amplifiers on both 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

BASIC QUALIFICATIONS:

• Bachelor’s degree in materials science, mechanical engineering, electrical engineering, physics, chemical engineering, or other STEM discipline
• 1+ years of experience in hardware development, failure analysis, or reliability engineering (internships, co-ops, and extracurriculars acceptable)

PREFERRED SKILLS AND EXPERIENCE:

• Master’s degree in STEM discipline
• Excellent problem-solving, communication, and technical writing skills
• Experience with electronics, mechanical design, analysis, and knowledge of RF principles
• Direct experience with hardware failure analysis tools and techniques (SEM, FIB, EDS, cross-sectioning, fault isolation, or equivalent)
• Experience analyzing complex datasets with Python, AI

ADDITIONAL REQUIREMENTS:

• Ability to work overtime and weekends as needed for mission critical dead lines
• Ability to work in a cleanroom or ESD-controlled environment when required

COMPENSATION AND BENEFITS:

• Level 1: $100,000.00 - $135,000.00
• Level 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 SpaceX. 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 SpaceX 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.

SpaceX is an Equal Opportunity Employer; employment with SpaceX 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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