Materials Engineer - Solar Cell Characterization

MATERIALS ENGINEER, SOLAR CELL CHARACTERIZATION

Starlink is building the world's largest satellite constellation to deliver fast, reliable internet to people who need it most—and powering that constellation starts on the factory floor. We are insourcing solar cell manufacturing end-to-end, from crystal growth and ingot production through wafering and cell fabrication, to drive performance, cost, and scale at every step. High-efficiency, high-reliability cells made in-house are the backbone of the Starlink network: more photons in means more data out to customers around the world.

As a Materials Engineer for solar cell characterization, you will own offline metrology and materials characterization of insourced solar cells—building the measurement capability, analysis methods, and physical understanding needed to raise cell performance and yield. You will turn electrical, optical, and materials data into root cause, and interface with process, production, and quality teams to lock in durable fixes. If you are passionate about solving hard problems, anchor your engineering judgment with first-principles thinking, and are relentless about acting with urgency, this role is for you.

RESPONSIBILITIES:

• Own characterization and metrology strategy for insourced solar cells across cell interfaces—from method development and tool qualification through production-ready measurement recipes
• Build and maintain a suite of offline electrical, optical, and materials characterization techniques to quantify cell performance, reliability, and yield-limiting defects (e.g., I-V, quantum efficiency, PL/EL imaging, lifetime, SEM-EDS, optical microscopy, spectroscopy, and related methods)
• Lead root cause analysis for performance and yield excursions: design experiments, execute failure analysis, correlate process history with metrology signatures, and drive corrective actions to first principles
• Define measurement requirements, sampling plans, gauge R&R, calibration, and acceptance criteria in partnership with process, quality, and production engineering
• Stand up and develop processes for offline metrology equipment; own data integrity, tool matching, and measurement uncertainty so results can be trusted for process decisions
• Translate characterization results into clear material and process recommendations that improve efficiency, reliability, cost, and manufacturability
• Partner with process engineering on DOEs and golden-line development; provide rapid feedback loops during recipe, materials, and equipment changes
• Document methods, specifications, FA reports, and best practices; communicate status, risks, and recommendations clearly to cross-functional partners and leadership
• Champion a culture of safety and quality in all sample preparation, chemical handling, lab operations, and production support activities

BASIC QUALIFICATIONS:

• Bachelor's degree in materials science, materials engineering, chemical engineering, or a related technical discipline
• 1+ years of professional experience in materials characterization, failure analysis, semiconductor/PV metrology, or a related laboratory or manufacturing role (internship and co-op experience applicable)

PREFERRED SKILLS AND EXPERIENCE:

• Master's degree or PhD in materials science, materials engineering, chemical engineering, or a related technical discipline
• Hands-on experience characterizing photovoltaic devices, silicon wafers, thin films, or semiconductor devices
• Proficiency with solar cell and wafer metrology such as I-V, Suns-Voc, EQE/IQE, photoluminescence, electroluminescence, minority-carrier lifetime (QSSPC/PL), ellipsometry, four-point probe, and optical inspection
• Experience with materials analysis techniques including SEM-EDS, FIB cross-sectioning, AFM, XRD, FTIR, XPS, SIMS, ICP-MS, and optical microscopy
• Experience designing and implementing a laboratory inventory management system (including architecture, workflows, and user access), building automated pipelines to transfer metrology data from tools into the LIMS, and integrating SPC (control charts, dashboards, and alerts) on the collected data
• Demonstrated ability to lead structured root cause analysis (e.g., DOE, 5-why, fishbone, fault-tree) and convert findings into process or material improvements
• Experience qualifying metrology tools, writing measurement SOPs, and establishing statistical process controls or gauge capabilities
• Experience working in a high-volume manufacturing or fab environment and partnering with process, quality, and production teams
• Strong first-principles problem solving and a demonstrated ability to dig deep on ambiguous materials and device-performance challenges
• Comfortable with data analysis (Python, JMP, MATLAB, or equivalent) to correlate metrology, process, and electrical results
• Passion for building, learning quickly, and owning outcomes end-to-end; thrives in a fast-paced environment with tight timelines
• Effective written and verbal communication skills; able to convey technical concepts across all levels of the organization
• Self-motivated with strong organizational skills and a bias toward action

ADDITIONAL REQUIREMENTS:

• Willingness to travel to other SpaceX sites and/or vendors as needed (up to 25%)
• Ability to lift up to 25 lbs unassisted
• Ability to stand/walk for extended periods in the lab and on the manufacturing floor
• Willingness to work extended hours and weekends as needed to support manufacturing, tool bring-up, and critical milestones
• Must be able to wear appropriate PPE for lab and manufacturing environments