Sr. Mechanical Engineer, Insource Manufacturing (Starlink)

SPACE EXPLORATION TECHNOLOGIES CORP; Bastrop (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

SPACE EXPLORATION TECHNOLOGIES CORP is seeking a Sr. Mechanical Engineer for its Insource Manufacturing team in Bastrop, TX. This role involves owning the design and optimization of critical manufacturing equipment for Starlink products, emphasizing high-volume production efficiency.

The ideal candidate will have at least 5 years of relevant experience and a bachelor's degree in mechanical engineering. Responsibilities include collaborating with cross-functional teams to enhance manufacturing processes and ensure equipment reliability.

Qualifications

• 5+ years of professional mechanical design or manufacturing experience.
• 3+ years of experience with CAD and FEA software packages.

Responsibilities

• Own manufacturing subsystems and equipment from design through production.
• Develop design criteria and collaborate with cross-functional teams.
• Perform FMEA, reliability modeling, and stress testing.

Skills

Mechanical design

CAD and FEA software

Manufacturing processes

Project management

Education

Bachelor’s degree in mechanical engineering or related field

Tools

Siemens NX

Teamcenter

Job description

Sr. Mechanical Engineer, Insource Manufacturing (Starlink)

Bastrop, TX

SpaceX was founded under the belief that a future where humanity is exploring the stars is more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

The Insource Manufacturing team is responsible for designing, building, and qualifying custom equipment and automation systems to enable high-volume production of Starlink products. As a Mechanical Engineer in this group, you will take end‑to‑end ownership of critical manufacturing equipment and material handling systems. This role requires a detail‑oriented engineer who is passionate about designing robust mechanical and automation systems, optimizing existing equipment, and developing novel solutions that push the boundaries of high-volume manufacturing while minimizing risk and maximizing efficiency in our state‑of‑the‑art Starlink factory.

Responsibilities

• Own manufacturing subsystems and equipment from conceptual design through fabrication, commissioning, and high-volume production ramp
• Develop design criteria, collaborate on requirements with cross-functional teams, and drive system-level optimization
• Perform failure modes and effects analysis (FMEA), reliability modeling, and stress testing to predict and mitigate potential failures and improve overall equipment effectiveness (OEE)
• Design and develop production equipment including structures, mechanisms, robot end effectors, automation systems, and material handling solutions
• Uptime Optimization: Monitor and track equipment performance metrics using data analytics; identify bottlenecks and downtime causes, then implement preventive and predictive maintenance strategies to maximize operational availability
• Evaluate and select equipment suppliers and vendors based on reliability, performance, and business needs; oversee installation, commissioning, and ongoing performance of both internally designed and vendor-supplied equipment
• Demonstrate extreme ownership of projects through their entire lifecycle while balancing multiple initiatives in a fast-paced environment
• Collaborate closely with design, manufacturing, and test teams to develop products and production processes in parallel
• Solve complex, open-ended problems with an emphasis on speed of execution, efficiency, and scalability

Basic Qualifications

• Bachelor’s degree in mechanical, manufacturing, materials, or other engineering discipline
• 5+ years of professional experience with mechanical design, analysis, testing, or manufacturing (internship experience is applicable)
• 3+ years of experience with CAD and FEA software packages

Preferred Skills and Experience

• Master’s degree or PhD in an engineering discipline
• 3+ years of experience in a leadership position in a manufacturing environment
• Experience with custom machine design including electromechanical systems, end-of-arm tooling, motors, actuators, linear rails, bearings, and lifting/rigging
• Proficient in 3D CAD (Siemens NX preferred) and Teamcenter
• Solid understanding and application of GD&T, mechanical engineering fundamentals, structural analysis, and failure modes of complex mechanical systems
• Prior ownership of a complex component or assembly from initial design through production ramp
• Experience applying common manufacturing processes (welding, machining, assembly, inspection) and designing for manufacturability
• Hands‑on experience with mills, lathes, manual and CNC machines
• Experience with FEA, structural hand calculations, and sizing of mechanical components
• Self-motivated with strong organizational, written, and oral communication skills

Additional Requirements

• Willingness to travel to other SpaceX sites and/or vendors for significant/extended periods of time (~25% travel normally, more during urgent manufacturing and test campaigns)
• Ability to lift up to 25 lbs unassisted
• Standing/walking for long periods of time
• Ability to work long hours and weekends as necessary to support critical milestones
• 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.

SpaceX is an Equal Opportunity Employer; employment with SpaceX 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.