Mechanical Engineer, Aviation (Starlink)

MECHANICAL ENGINEER, AVIATION (STARLINK) 

At SpaceX we’re leveraging our experience in building rockets and spacecraft to deploy Starlink, the world’s most advanced broadband internet system. Starlink is the world’s largest satellite constellation and is providing fast, reliable internet to 3M+ users worldwide. We design, build, test, and operate all parts of the system – thousands of satellites, consumer antennae that allow users to connect within minutes of unboxing, and the software that brings it all together. We’ve only begun to scratch the surface of Starlink’s potential global impact and are looking for best-in-class engineers to help maximize Starlink’s utility for communities and businesses around the globe.

As a Starlink Mechanical Engineer on the Aviation Engineering Team, you will own flight hardware from cradle to grave and will interact regularly with senior leadership during critical design phases, ushering in the next era of airborne connectivity! In this role you will own design, qualification, test design, production success, integration design, and in-flight success of flight hardware. This role demands strong technical, design, analysis skills, and the drive to get your work over the finish line as well as close coordination with electrical teams to realize high reliability hardware. Come join the team putting bringing the most incredible in-flight internet the world has ever seen!

RESPONSIBILITIES: 

• Develop and drive Starlink integration design packages from site survey through design, substantiation, and qualification
• Own Starlink Aviation hardware from conceptual design through production and operation for aircraft installations
• Develop design criteria, collaborate on requirements, and drive system-level optimization
• Perform analysis on designs including hand calculations, FEA, and CAD in a rapidly changing environment
• Rapidly iterate on designs and analysis to inform high level systems trades and steer overall product direction
• Lead design reviews and work with FAA designees to certify components and systems
• Generate detailed production and integration drawings using GD&T and performing a tolerance stack-up analysis
• Drive holistic DFM to create elegant designs with a focus on piece part and process count reductions, error proofing at every step of fabrication and integration, and consistent performance and production metrics
• Establish an efficient product lifecycle starting in the supply chain all the way through final integration that balances cost, complexity, and quality; work closely with partner teams to design and realize an efficient in-house production line
• Perform environmental and performance testing on hardware to validate analysis and demonstrate compliance to design criteria
• Own product delivery timeline through conception, design, assembly, and launch
• Demonstrate extreme ownership of product outcomes at every stage of development and production 

BASIC QUALIFICATIONS: 

• Bachelor's degree in Mechanical, Electrical or Aerospace Engineering
• Experience with CAD and FEA software packages 
• 1+ years of professional experience with mechanical/electromechanical design, analysis, testing, and/or manufacturing

PREFERRED SKILLS AND EXPERIENCE: 

• Master’s degree in engineering or a related technical discipline
• 3+ years of professional experience in mechanical design and analysis
• 2+ years of hands-on project experience with complex mechanical systems
• Proficient in 3D CAD (NX preferred)
• Solid understanding and application of GD&T
• Demonstrated understanding of structural analysis and failure modes of complex mechanical systems
• Prior ownership of a complex component or assembly from initial design through high-volume production ramp
• Self-motivated with strong organizational, written, and oral communication skills 

Some preferred skills and experience depend on the specific team within Starlink mechanical engineering, and may include: 

• Knowledge of and experience in selecting materials, manufacturing methods, and surface treatments for mechanical components 
• Proficiency in one or more programming languages
• Experience working with PCB designers and exposure to PCB layout and PCBA mechanical design
• Experience with design of experiments, statistical process control, and process qualification
• Specific expertise applicable to any of the above sub-teams 

ADDITIONAL REQUIREMENTS: 

• Ability to work long hours and weekends as necessary to support critical milestones 
• Some travel will be required (~20%)

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Last updated on Jul 26, 2024