Sr. High Pressure Die Casting Analysis Engineer (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. HIGH PRESSURE DIE CASTING ANALYSIS ENGINEER (STARLINK)

SpaceX is leveraging its 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 4M+ users worldwide. We design, build, test, and operate all parts of the system – thousands of satellites, consumer products 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. As we continue to upgrade and expand the constellation, we’re looking for best-in-class engineers to join the team.

As a High Pressure Die Casting (HPDC) Analysis Engineer, you will play a key role in optimizing the manufacturing processes for our Starlink consumer hardware. From the initial design phase through tooling qualification, you will apply fundamental physics-based numerical analysis to push the limits of casting. The result will be enhancing die performance, streamlining production processes, and minimizing material waste. Your contributions will directly support the growth and success of the Starlink program as we expand our global broadband service.

RESPONSIBILITIES: 

• Inform engineering teams by offering your expertise in die casting, identifying ways to enhance manufacturability and mold performance


• Collaborate with engineers on design for manufacturability (DFM), addressing potential manufacturability challenges before the tooling phase


• Work with engineers to optimize casting computer simulation algorithms to develop excellent correlation to real world behavior


• Use models to identify and guide future casting development projects


• Make use of advanced casting simulation tools to boost production operations, reduce material waste, and ensure every part meets the highest standards of quality


• Analyze data from simulations to improve die casting processes, contribute to a more efficient production cycle, and push end product performance

BASIC QUALIFICATIONS:

• Bachelor’s degree in mechanical, materials engineering, or other engineering discipline


• 5+ years of experience running multi-physics process simulation software


• 3+ years of experience working with casting machines and operations, setup, or processing of molds and auxiliary equipment

PREFFERED SKILLS AND EXPERIENCE: 

• Experience with computer languages such as Python, C++, SQL, or similar


• Excellent knowledge of engineering for HPDC processing, tooling, and troubleshooting


• 2+ years experience with analysis tools and methods to solve technical problems (e.g. 3D modeling, mold filling analysis, finite element analysis)


• Experience with software tools such as Docker, Git, Pandas, and similar


• Expertise in commercial casting process simulation software such as MAGMAsoft, Flow3D, EKK, or similar


• Understanding of DFM, with the ability to provide early design feedback


• Ability to work with cross-functional teams and suppliers


• Ability to analyze and interpret HPDC simulations to diagnose issues and optimize design, material use, and cycle times


• Understanding of HPDC processes, tooling design, and mold performance for high-volume production of consumer hardware

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].