Sr. Materials Engineer, AI Satellites (Starmind)

United States Digital Space LLC; Bastrop (TX); On-site; USD 120,000 - 160,000; Full time

Job summary

United States Digital Space LLC in Bastrop, TX, seeks a Sr. Materials Engineer for AI satellites. You will own the hardware materials lifecycle, from spec to validation, enabling high-performance on-orbit AI compute.

You’ll work across mechanical, thermal, and electrical teams to push reliability in extreme space environments. The role requires a strong background in microelectronics packaging, materials characterization, and QA, with 5+ years in related research or manufacturing.

Qualifications

• Bachelor's degree in materials science, mechanical engineering, or other engineering discipline
• 5+ years of experience in microelectronics device research or manufacturing

Responsibilities

• Rapidly develop high-reliability microelectronics packages, cooling systems, and radiator hardware for satellites.
• Own the full lifecycle of materials specification, validation, and process development— including device modeling, characterization of performance metrics, and materials failure analysis.
• Drive system trades, requirements capture, materials selection, prototyping, manufacturing, failure analysis.
• Build supply chains for build-up layers, plating chemicals, coatings, thermal interface materials, and other materials for compute and satellite manufacturing. Define incoming acceptance criteria for materials.
• Address materials and process challenges in advanced packaging while spearheading the development of next-generation TIM materials to improve packaging performance.
• Specify and implement in-process metrology tools for quality control. Design thermal test vehicles and test setups to evaluate material/electronic properties. Integrate simulation tools with experimental data to guide and drive targeted improvements via material or process changes.
• Work closely with engineers from adjacent disciplines (mechanical, thermal, electrical, software, test engineering, supply chain, silicon design, etc.) to deliver tightly integrated, high-performance hardware

Skills

Materials engineering

Thermal management

Microelectronics

Reliability testing

Problem solving

Education

Bachelor's in materials science or mechanical engineering

Advanced degree (preferred)

Tools

Python

MATLAB

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.

SR. MATERIALS ENGINEER, AI SATELLITES (STARMIND)

the company is leveraging its experience deploying and operating the world’s largest satellite constellation to develop Starmind, a new constellation of satellites capturing solar energy in space to power low-cost, high-performance AI compute for Earth. Realizing this vision demands highly reliable, high performance electrical compute hardware, solar power systems, thermal radiators, and more. These systems must operate in the extreme environment of space while delivering the connectivity, control, power distribution, and processing needed for orbital AI inference.

The Starmind team designs, builds, and operates the orbital compute fabric of the future. We develop nearly every key piece of technology in house – from the satellites’ flight computers and power systems to the fully custom compute electronics, memory, and networking that form the brain of our on-orbit data centers. As a Materials Engineer on the Starmind team, you’ll have ownership over the entire life-cycle of the hardware that enables advanced on-orbit AI processing and data center workloads. Your work sits at the intersection of process, packaging, mechanical, and thermal engineering. The Payload team is responsible for the design of industry-leading compute electronics, memory, and networking in order to achieve required domain sizes and processing workloads.

RESPONSIBILITIES:

• Rapidly develop high-reliability microelectronics packages, cooling systems, and radiator hardware for satellites.
• Own the full lifecycle of materials specification, validation, and process development— including device modeling, characterization of performance metrics, and materials failure analysis.
• Drive system trades, requirements capture, materials selection, prototyping, manufacturing, failure analysis.
• Build supply chains for build-up layers, plating chemicals, coatings, thermal interface materials, and other materials for compute and satellite manufacturing. Define incoming acceptance criteria for materials.
• Address materials and process challenges in advanced packaging while spearheading the development of next-generation TIM materials to improve packaging performance.
• Specify and implement in-process metrology tools for quality control. Design thermal test vehicles and test setups to evaluate material/electronic properties. Integrate simulation tools with experimental data to guide and drive targeted improvements via material or process changes.
• Work closely with engineers from adjacent disciplines (mechanical, thermal, electrical, software, test engineering, supply chain, silicon design, etc.) to deliver tightly integrated, high-performance hardware
• Challenge assumptions, question requirements, learn from your mistakes, and approach problems with an open mind
• Manage compliance risks related to materials and processes, ensuring safety and environmental compliance with industry standards.
• Collaborate closely with leadership and stakeholders across all departments—including design, reliability, production, and supply chain—to integrate materials innovations into product roadmaps and ensure accountability for operations and reliability.

BASIC QUALIFICATIONS

• Bachelor's degree in materials science, mechanical engineering, or other engineering discipline
• 5+ years of experience in microelectronics device research or manufacturing

PREFERRED SKILLS AND EXPERIENCE:

• Advanced degree in materials science or similar field
• Experience in hardware, robotics, automation, or manufacturing environments
• Experience designing tooling, fixtures, or jigs for assembly or test applications
• Exposure to scripting or data analysis tools (e.g., Python, MATLAB, or equivalent) for process data analysis or automation
• Experience working with precision assemblies, robotic systems, or automated pick-and-place equipment
• Familiarity with manufacturing process development methodologies (e.g., PFMEA, process capability studies, SPC)
• Experience with or interest in production data systems, MES, or manufacturing traceability infrastructure
• Familiarity with cleanroom or controlled-environment manufacturing practices

ADDITIONAL REQUIREMENTS:

• Ability to work extended hours or weekends as needed for mission critical deadlines
• Some travel may occasionally be required

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 affirmative action plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to [e-mail].