Sr. Manufacturing Engineer (Starship)

SENIOR BUILD ENGINEER (STARSHIP)

The Build Engineer role is responsible for taking design-for-manufacturability concepts through to integration and testing of the full vehicle. Build Engineers will be deeply involved in the primary and secondary structures of Starship and Super Heavy, including the design of tooling (assembly aids, welding fixtures, part fixturing, etc.) and the development of processes for welding, large part movement, and major structure integration. This role will rapidly develop early versions of the vehicles and later transition into integration operations sequencing and the installation of flight-critical hardware. Throughout the program, Build Engineers will document processes and drive continuous improvement for future builds. Engineers in this role will also be expected to act as de facto technical supervisors and advisors to production technicians, welders, and other skilled trades.

RESPONSIBILITIES:

• Work closely with vehicle analysts and the design team to ensure hardware meets both vehicle design requirements and manufacturing process constraints
• Develop production procedures and manage the transition of parts and assemblies from development to high-rate production
• Coordinate and execute development, qualification, and acceptance testing of tooling and systems required to meet hardware deadlines
• Identify and implement design-for-manufacturability (DFM) improvements to increase production efficiency
• Create original CAD models and drawings for flight hardware and tooling
• Serve as the primary on-site design engineering point of contact for efficient build and assembly of parts and vehicle systems
• Create and maintain build schedules
• Analyze and resolve manufacturing discrepancies, working closely with the Quality team on issues related to design, fabrication, and assembly
• Participate in design reviews with internal teams, suppliers, and customers
• Partner with engineering and production teams to generate ideas and improvements for current and next-generation vehicles
• Provide technical direction and support to vendors; assist in sourcing and qualifying new suppliers

BASIC QUALIFICATIONS:

• Bachelor’s or advanced degree in Aerospace Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Engineering, or Engineering Physics
• Hands-on project experience with complex mechanical systems, preferably as a team or sub-team lead
• 5+ years of professional engineering experience

PREFERRED SKILLS AND EXPERIENCE:

• Experience working on SpaceX vehicles or builds
• Strong experience with GD&T
• Experience with large steel structure fabrication and assembly (civil, naval, aerospace, or heavy mechanical)
• Experience leading the mechanical design of operationally critical hardware, including structures and basic structural analysis
• Proficiency with Finite Element Analysis (FEA)
• Experience developing, maintaining, and improving welding processes
• Experience with process development, facility/line layouts, and error-proofing (poka-yoke)
• Experience with Siemens NX and Teamcenter (CAD and PLM systems)
• Strong interpersonal, organizational, and communication skills

ADDITIONAL REQUIREMENTS

• Flight hardware typically is built in tight quarters and physical dexterity is required
• Ability to perform job duties that require standing, kneeling, crouching, twisting upper body, working in cramped positions in small openings and climbing hand over hand
• Typically exposed to work in extreme outdoor environments – heat, cold, rain
• Work performed in an environment requiring exposure to fumes, odors, and noise
• Schedule varies depending on site operational needs; flexibility required
• Flexibility to travel to remote build sites, up to 10%
• Stand: Up to 6 hours per day
• Sit: Up to 6 hours per day
• Push/Pull: Up to 50lbs. (unassisted) 30 minutes to 1 hour per day
• Overhead reach: Up to 1 hour per day
• Walk: Up to 1 hour per day
• Lift/Carry: Up to 25lbs. (unassisted) 30 minutes to 1 hour per day
• Climb (ladder/stairs): Up to 6 hours per day
• Kneel/Crouch: Up to 6 hours per day
• Upper body twist: Up to 6 hours per day
• Ability to work in temperatures over 80 degrees 6 hours or greater per day
• Candidate must be capable of safely working at heights (up to 500ft), in confined spaces, using an air purifying respirator, operating heavy equipment and machinery, and performing the physical requirements of the job listed in the job description
• Candidate may be required to complete a pre-employment questionnaire and/or physical to confirm these capabilities, which may include a medical history review