Supplier Development Engineer, Assembly Processes (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. SUPPLIER DEVELOPMENT ENGINEER, ASSEMBLY PROCESSES (STARLINK) Starlink User Terminal business is experiencing exponential growth across consumer, retail, enterprise, and mobility applications. This rapid expansion requires a highly resilient and scalable supply chain with world-class precision assembly processes at contract manufacturers. The role entails early engagement in supplier selection, equipment selection, and process engineering to set programs up for success in high-volume manufacturing by ensuring material and process corners are fully completed. The role also includes ownership to deliver on time, monitor field performance, react to issues, and feed lessons learned back to engineering teams for iterative improvement. We are seeking a technically strong Supplier Development Engineer to drive equipment bring-up and process development for critical joining, dispensing, and inspection technologies. This role focuses on developing robust, high-volume manufacturing processes for hardware to be manufactured at contract manufacturers, with emphasis on plastic and metal joining methods, precision material dispensing, and automated quality inspection. The Supplier Development Engineer, Assembly Processes will be responsible for end-to-end process development and qualification of joining, dispensing, and inspection systems. This position demands deep manufacturing process expertise and extreme ownership from early equipment selection through process characterization, line qualification, and field performance feedback. RESPONSIBILITIES: Own end-to-end process development, equipment bring-up, and qualification for precision assembly technologies at contract manufacturers, spanning strategic supplier selection, new product introduction (NPI), and high-volume production Engage early with suppliers on equipment selection, tooling design, and process engineering to properly set up high-volume manufacturing programs by ensuring material and process corners are fully characterized and completed Lead development of ultrasonic welding processes, including amplitude, force, energy, weld time, and trigger optimization, as well as horn design, joint geometry, and weld strength validation for both metal and thermoplastic components Develop hot plate welding and vibration welding processes for plastic housings and enclosures, focusing on temperature uniformity, platen design, melt displacement control, weld pressure profiles, and long-term joint durability Optimize heat staking and hot riveting processes for plastic boss forming, including temperature control, pressure profiling, staking tool design, and dimensional stability validation Develop and qualify precision dispense processes for thermal interface materials (TIM), adhesives, and sealants, including rheological characterization, volumetric vs. time-pressure dispensing, needle selection, vision-guided positioning, and repeatable bead or dot formation Establish and optimize automated optical inspection (AOI) systems, including multi-angle lighting techniques, high-resolution imaging, algorithm development, false call reduction, and integration with deep learning-based defect detection Design and execute comprehensive design of experiments (DOE) and corner case studies (material and process windows) to define robust parameter ranges and ensure process capability across environmental and material variations Lead line qualification activities at contract manufacturers, including equipment installation qualification (IQ), operational qualification (OQ), performance qualification (PQ), gauge repeatability and reproducibility (GR&R), and production part approval process (PPAP) Develop detailed process control plans