Mechanical Engineer, Insource Manufacturing (Starlink)

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 • 1+ years of experience professional experience with mechanical design, analysis, testing, or manufacturing (internship experience is applicable) • 1+ years of experience with CAD and FEA software packages PREFERRED SKILLS AND EXPERIENCE: • 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. a7 1157, or (iv) Asylee under 8 U.S.C. a7 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.