Sr. Process Engineer - Wafer Level Assembly, AI Satellites (Starmind)

SPACE EXPLORATION TECHNOLOGIES CORP; Bastrop (TX); On-site; USD 120,000 - 160,000; Full time

Job summary

SpaceX Bastrop, TX seeks a Sr. Process Engineer to own the full lifecycle of advanced packaging for Wafer Level Assembly on the Starmind program. You will lead board-assembly process development, specify equipment, and drive qualification and ramp activities for satellite compute hardware.

You will collaborate with mechanical, thermal, and electrical teams to implement metrology tools, analyze data, and push cost reduction, efficiency, and reliability improvements across the manufacturing flow.

Qualifications

• Bachelor’s degree in chemical engineering or related field.
• 5+ years in microelectronics device research or manufacturing.
• Experience with hardware, robotics, automation, or manufacturing environments.
• Exposure to tooling, fixtures, or jigs for assembly or test applications.

Responsibilities

• Own full lifecycle of advanced packaging through board-assembly process development.
• Own equipment specification, qualification, and ramp.
• Build supply chains for die, packages, components, and equipment for satellite compute manufacturing.
• Specify in-process metrology tools for quality control and drive process improvements.
• Drive end-to-end process R&D programs to reduce cost and improve reliability.
• Collaborate with mechanical, thermal, materials, electrical, and software engineers.

Skills

Process engineering

Packaging

Manufacturing

Metrology

Data analysis

Education

Bachelor’s degree in chemical engineering

Tools

MATLAB

JMP

Job description

Sr. Process Engineer - Wafer Level Assembly, AI Satellites (Starmind)

Bastrop, TX

SpaceX was founded under the belief that a future where humanity is exploring the stars is fundamentally 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.

SpaceX 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 Sr. Process 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, materials, and thermal engineering.

Responsibilities

• Own the full lifecycle of advanced packaging through board‑assembly process development – including requirements capture, materials selection, prototyping, process optimization, manufacturing, and failure analysis.
• Own the full lifecycle of equipment specification, qualification, and ramp.
• Build supply chains for die, packages, components, consumable chemicals, and equipment for satellite compute manufacturing. Define incoming acceptance criteria for components and materials.
• Specify and implement in‑process metrology tools for quality control. Integrate simulation tools with experimental data to guide and drive targeted process improvements.
• Drive end‑to‑end process R&D programs, from concept through product implementation, to drive cost down, efficiency improvements, and reliability in electronic systems.
• Work closely with engineers from adjacent disciplines (mechanical, thermal, materials, electrical, software, test engineering, supply chain, silicon design, etc.) to deliver tightly integrated, high‑performance hardware.
• Challenge assumptions, question requirements, learn from mistakes, and approach problems with an open mind.
• Collaborate closely with leadership and stakeholders across all departments—including design, reliability, production, and supply chain—to deliver best‑in‑class electronics.
• Manage compliance risks, ensuring safety and environmental compliance with industry standards.
• Mentor and develop engineers, providing technical guidance and project oversight.

Basic Qualifications

• Bachelor’s degree in chemical engineering, materials science, mechanical engineering, or another engineering discipline.
• 5+ years of experience in microelectronics device research or manufacturing.

Preferred Skills and Experience

• 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., MATLAB, JMP) 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).
• Exposure to GD&T and tolerance analysis as applied to fixture and tooling design.
• 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.
• To comply with U.S. Government export regulations, applicant must be a U.S. citizen or national, U.S. lawful permanent resident, refugee, or asylee, or be eligible to obtain the required authorizations from the U.S. Department of State.

Equal Opportunity Employment

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.

Applicants wishing to view a copy of SpaceX’s Affidavit of the Equal Opportunity Employer plan for veterans and individuals with disabilities, or who require reasonable accommodation to the application/interview process, should reach out to [e-mail].