Sr. Materials Engineer (Starlink)

United States Digital Space LLC; Bastrop (TX); On-site; USD 120,000 - 180,000; Full time

Job summary

Starlink is seeking a Sr. Materials Engineer to own consumables for ingot through cell fabrication, ensuring specs and qualification processes meet high-volume manufacturing needs.

The role emphasizes materials fundamentals across metals, polymers, crystals, and coatings, with a focus on safety, quality, and urgent execution. Prior solar experience is welcome but not required.

Qualifications

• Bachelor’s in materials science, chemical engineering, or STEM field.
• 5+ years in materials engineering, supplier qualification, or manufacturing support.
• Master’s or PhD preferred in related field.
• Experience with metals, polymers, crystals, or coatings in manufacturing.

Responsibilities

• Own and drive consumable material strategy for ingot, wafer, and cell lines.
• Collaborate with supply chain, process engineering, quality, and production.
• Define material requirements, specs, and acceptance criteria.
• Lead material qualification programs with trials and reliability checks.
• Drive data-driven root-cause investigations and corrective actions.

Skills

Materials engineering fundamentals

First principles thinking

Cross-functional collaboration

Technical problem solving

Education

Bachelor's degree in materials science or chemical engineering

MS/PhD preferred

Tools

SEM-EDS

XRD

FTIR

XPS

Optical microscopy

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 (STARLINK)

Starlink is building the world’s largest satellite constellation to deliver fast, reliable internet to people who need it most—and powering that constellation starts on the factory floor. We are insourcing solar cell manufacturing end-to-end, from crystal growth and ingot production through wafering and cell fabrication to drive performance, cost, and scale at every step. High-efficiency, high-reliability cells made in-house are the backbone of the Starlink network: more photons in means more data out to customers around the world.

As a Sr. Materials Engineer, you will own critical consumables that enable our end-to-end solar cell manufacturing—from ingot growth through wafering and cell fabrication. You will set the technical bar for materials sourcing, qualification, and production hand-off, solving the hardest materials and supply‑chain challenges that stand between us and reliable, high-volume cell production. We are looking for a general Materials Engineer who brings deep fundamentals across metals, polymers, crystals, and process consumables—solar experience is welcome but not required. If you are passionate about solving hard problems, anchor your engineering judgment with first principles thinking, and are relentless about acting with urgency, this role is for you.

RESPONSIBILITIES:

• Own and drive strategy for consumable materials across ingot, wafer, and/or solar cell manufacturing lines—from supplier selection and technical evaluation through qualification, production hand-off, and long-term lifecycle management.
• Lead cross-functional efforts with supply chain, process engineering, quality, and production to source, qualify, and dual-source critical materials that reduce risk and support aggressive scale and cost targets.
• Define and own material requirements, specifications, and acceptance criteria; ensure they accurately reflect process needs, quality standards, and manufacturability at rate.
• Architect and execute rigorous material qualification programs—including characterization, process trials, reliability assessment, and production-readiness reviews—then drive clean hand-off into manufacturing.
• Lead root cause investigations to first principles and implement durable, data-driven corrective actions with urgency.
• Apply deep materials fundamentals across metals, polymers, crystals, coatings, and other process consumables to anticipate failure modes, guide selection, and unlock performance or cost gains.
• Identify and champion path‑finding material opportunities that deliver measurable improvements in yield, reliability, uptime, and cost.
• Mentor peers and partner teams on materials problem solving, engineering judgment, and qualification best practices.
• Communicate technical status, risks, and strategic recommendations to leadership.
• Champion a culture of safety, quality, and extreme ownership in all materials and manufacturing activities.

BASIC QUALIFICATIONS:

• Bachelor's degree in materials science, chemical engineering, or a STEM field.
• 5+ years of experience in materials engineering, materials selection, process materials, supplier qualification, or manufacturing materials support.

PREFERRED SKILLS AND EXPERIENCE:

• Master’s degree or PhD in materials science, chemical engineering, or a related field.
• Proven track record owning materials from concept or sourcing through qualification and high-volume production.
• Broad hands‑on experience with metals, polymers, crystals, ceramics, coatings, adhesives, or other process consumables in a manufacturing or R&D environment.
• Experience partnering with supply chain on technical sourcing, supplier development, dual‑sourcing, and reducing single‑source risk for critical materials.
• Strong expertise in materials characterization (e.g., SEM‑EDS, XRD, FTIR, XPS, optical microscopy, mechanical/chemical property testing) and linking material/process variables to performance.
• Demonstrated ability to lead ambiguous, high‑scope technical problems; apply first principles, iterate rapidly, and deliver durable solutions under aggressive timelines.
• Hands‑on experience in a high‑volume manufacturing environment; comfortable on the production floor and partnering closely with operators, process engineers, and quality teams.
• Passion for building, mentoring, and owning outcomes end‑to‑end; thrives in a fast‑paced, scrappy environment with tight timelines and aggressive schedules.
• Excellent written and interpersonal communication skills; able to influence and convey technical concepts across all levels of the organization.

ADDITIONAL REQUIREMENTS:

• Willingness and ability to travel up to 25% time.
• Ability to lift up to 25 lbs unassisted.
• Ability to stand/walk for extended periods on the manufacturing floor.
• Willingness to work extended hours and weekends as needed.

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 Aff…