Sr. Mechanical Engineer, Insource Manufacturing (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. 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