Senior Metals Engineer - Aerospace Weld & Alloys

SpaceX; Redmond (WA); On-site; USD 135,000 - 220,000; Full time

Benefits offered by this job

Stock options

Long-term incentives

Employee stock purchase plan

Medical, vision & dental

401(k) plan

Paid time off

Shuttle service

Job summary

SpaceX in Redmond, WA is seeking a Sr. Materials Engineer, Metals to lead materials selection, qualification, and joining processes for Starlink hardware.

You’ll develop and qualify metallic alloys and joints, perform failure analysis, and work with suppliers to deliver high‑volume production in a fast‑paced environment. The role requires a bachelor’s in a materials field, 5+ years with aluminum alloys and welding, plus hands‑on experience with SEM‑EDS, hardness testing, and metallurgy

Qualifications

• Bachelor’s degree in Materials Science, Materials Engineering, Welding Engineering, Metallurgical Engineering, or other Materials Engineering discipline.
• 5+ years of experience with aluminum alloys used for structural and non-structural applications; metal alloys used in electronic applications; and metal‑joining processes (welding, brazing, soldering, sintering).
• Master's or PhD in Material Science, Materials Engineering, Weld Engineering, Metallurgical Engineering, or other Materials Engineering discipline.
• Experience with characterization techniques and equipment, including SEM-EDS, optical microscopy, hardness testers, mechanical property testing, and spectroscopy techniques for composition or phase.
• Strong interpersonal and collaborative skills with enthusiasm for the team’s spirit of innovation in cutting‑edge technology.
• First principles understanding of welding processes, weld strength testing methodologies, and standards used to make informed welding decisions.
• Hands‑on experience with metal‑joining technologies (welding, brazing, soldering, sintering) in a high‑production manufacturing environment.
• Experience with failure analysis, materials testing labs, ASTM/NASA/AMS specs, or supplier management.
• Experience with technical review of materials and processes and a sound understanding of the interaction between process variables and the resulting material performance.
• Demonstrated track record of success in a rapidly growing, fast‑paced, highly competitive, and scrappy entrepreneurial environment that operates under tight timelines and aggressive schedules.
• Effective written and interpersonal communication skills.

Responsibilities

• Provide materials selection, characterization, qualification, and manufacturing process support for metallic and metal‑joined hardware on Starlink satellites and ground infrastructure assemblies.
• Develop mechanical and physical properties of metallic alloys and joints for the design community, including data, allowables, and process recommendations.
• Perform root cause investigations and failure analysis using fractography, metallography, SEM-EDS, optical microscopy, and other characterization testing.
• Develop, qualify, troubleshoot, and optimize metal joining processes (welding, brazing, soldering, sintering) used in production, including understanding of process variables and resulting material performance.
• Provide technical review and advising for design efforts as it relates to material alloy selection, material & process specifications, fracture requirements, and design‑for‑manufacturability.
• Collaborate with suppliers on qualification, property development, and issue resolution for custom‑manufactured forgings, castings, and other metallic components.

Skills

Materials science

Welding & joining

Aluminum alloys

Failure analysis

Mechanical properties

Supplier collaboration

Education

Bachelor’s degree in Materials Science or related field

Master's or PhD in Materials Science/Engineering

Tools

SEM-EDS

Optical microscopy

Hardness testing

Metallurgy testing

Spectroscopy

Job description

SpaceX in Redmond, WA is seeking a Sr. Materials Engineer, Metals to lead materials selection, qualification, and joining processes for Starlink hardware.

You’ll develop and qualify metallic alloys and joints, perform failure analysis, and work with suppliers to deliver high‑volume production in a fast‑paced environment. The role requires a bachelor’s in a materials field, 5+ years with aluminum alloys and welding, plus hands‑on experience with SEM‑EDS, hardness testing, and metallurgy