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