Sr. Materials Engineer, Metals (Starlink)

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

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, METALS (STARLINK)

At the company, we’re leveraging our rocket and spacecraft expertise to deploy Starlink, the world’s largest and most advanced satellite constellation, delivering fast internet to over10million users worldwide. We design, build, test, and operate the full system — from thousands of satellites to user terminals and software.

We’re revolutionizing the launch market through rapid reusability and cutting-edge technology. As a Sr. Materials Engineer, you’ll take a hands‑on role in developing, implementing, and troubleshooting advanced material systems. You’ll use your expertise, experience, and creativity to solve complex material selection and processing challenges as we scale Starlink for high-volume production.

RESPONSIBILITIES:

• Provide materials selection, characterization, qualification, and manufacturing process support for metallic and metal‑joined (welded, brazed, soldered) 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.

BASIC 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).

PREFERRED SKILLS AND EXPERIENCE:

• 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/AMSspecs, or supplier management.

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