Sr. Mechanical Engineer, Insource Manufacturing (Starlink)

SpaceX 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 SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars. SR. MECHANICAL ENGINEER, INSOURCE MANUFACTURING (STARLINK)   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 25Ibs unassisted   Standing/walking for long periods of time   Ability to work long hours and weekends as necessary to support critical milestones   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 .   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 Affirmative Action Plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to  [email protected] .