Senior Metals Materials Engineer – Aerospace Joining

United States Digital Space LLC; Redmond (WA); On-site; USD 140,000 - 190,000; Full time

Job summary

Starlink is seeking a Senior Materials Engineer, Metals to lead materials selection, characterization, and joining processes for spacecraft hardware. You will develop alloys and welding procedures, perform root-cause analyses, and guide design decisions to ensure reliable high‑volume production for satellite and ground infrastructure.

You will work hands‑on with advanced material systems, collaborate with suppliers, and troubleshoot manufacturing challenges in a fast‑paced, high‑growth

Qualifications

• Bachelor’s degree in Materials Science, Materials Engineering, Welding Engineering, Metallurgical Engineering, or related 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).

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

Team collaboration

Problem solving

Welding knowledge

Material science

Education

Bachelor’s degree in Materials Science or related

Master’s or PhD in Materials Engineering or related field

Tools

SEM-EDS

Optical microscopy

Hardness testers

Spectroscopy

Mechanical testing

Job description

Starlink is seeking a Senior Materials Engineer, Metals to lead materials selection, characterization, and joining processes for spacecraft hardware. You will develop alloys and welding procedures, perform root-cause analyses, and guide design decisions to ensure reliable high‑volume production for satellite and ground infrastructure.

You will work hands‑on with advanced material systems, collaborate with suppliers, and troubleshoot manufacturing challenges in a fast‑paced, high‑growth