Senior Materials Engineer - Thin Films

SR. MATERIALS ENGINEER, THIN FILMS

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 Sr. Materials Engineer for thin films, you will partner with solar cell process engineering on PECVD-deposited films that set the optical and electrical performance of insourced cells. You will build deep understanding of film chemistry, microstructure, interfaces, and failure modes, then work with process, production, and quality teams to turn that insight into higher efficiency, yield, reliability, and cost. You will operate as a technical expert for the team: setting priorities from program needs, solving poorly defined materials problems autonomously, and raising the bar for how we specify, evaluate, and improve thin-film materials. 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:

• Partner with solar cell process engineering on PECVD thin films (e.g., passivation, anti-reflection, and related dielectric or semiconductor layers), developing materials requirements, film-property targets, and the physical understanding of how deposited films perform in the cell
• Build deep technical understanding of plasma-deposited film materials: composition, hydrogen content, density, stress, optical constants, passivation quality, interfaces, and reliability; translate that understanding into clear recommendations that improve cell performance and manufacturability
• Operate as the technical expert for thin-film materials: independently apply advanced materials concepts to highly complex issues, develop new characterization or evaluation methods where they do not already exist, and make high-impact materials decisions with limited tactical guidance
• Set your own priorities from program needs; execute multiple complex, multi-month materials projects in parallel (new film stacks, materials qualification, yield or reliability recovery, supplier materials) and come to leadership with solved problems and already-implemented solutions
• Partner with process engineering on DOEs and process trials: define materials-relevant responses, interpret how plasma, chemistry, and hardware changes affect film properties and cell results, and recommend durable improvements
• Define film material requirements, specifications, and acceptance criteria; qualify precursors, consumables, and film stacks so materials used in production are understood, controlled, and scalable
• Lead structured root cause analysis for materials-limited performance, yield, and reliability issues (film defects, interface failure, contamination, stoichiometry, stress, delamination); correlate process history with metrology (ellipsometry, lifetime, FTIR, SEM, I-V, and related methods) and drive corrective actions to first principles
• Influence cross-functional decisions with process, equipment, quality, production, and characterization teams; challenge assumptions that do not serve cell performance or manufacturability; create materials methods, specifications, and tools that raise the bar for others
• Identify and drive path-finding for advanced thin-film materials, stacks, or precursor chemistries that deliver measurable gains in efficiency, reliability, or cost
• Coordinate with suppliers on precursors, consumables, and film materials to reduce supply-chain risk and ensure long-term scalability
• Mentor engineers, new hires, and interns on thin-film materials, PECVD-relevant materials science, and first-principles problem solving; generate and share high-quality engineering content, specifications, and best practices
• Champion a culture of safety and quality in all vacuum, plasma, pyrophoric/toxic gas, chemical handling, lab, and production support activities

BASIC QUALIFICATIONS:

• Bachelor's degree in materials science, chemical engineering, electrical engineering, physics, or a STEM discipline
• 5+ years of professional experience with thin films, PECVD or other vacuum-deposited coatings, or electronic materials in a manufacturing or R&D environment

PREFERRED SKILLS AND EXPERIENCE:

• Master’s degree or PhD in materials science, chemical engineering, electrical engineering, physics, or a STEM discipline
• Hands-on experience with PECVD-deposited films in semiconductor or solar cell manufacturing
• Experience working closely with process engineering on PECVD or other vacuum deposition processes in a manufacturing or development environment
• Proficiency with thin-film and solar-cell metrology such as spectroscopic ellipsometry, reflectance, FTIR, minority-carrier lifetime (QSSPC/PL), SEM-EDS, XPS, four-point probe, film stress, and optical inspection
• Deep understanding of film growth mechanisms, precursor chemistry (e.g., SiH4, NH3, N2O, TMB, PH3), plasma/vacuum processing, and how film properties couple to solar-cell passivation and optics
• Demonstrated ability to lead structured root cause analysis (e.g., DOE, 5-why, fishbone, fault-tree) and convert findings into durable material or process recommendations
• Experience writing material specifications, qualifying precursors or film stacks, and establishing materials-related process-control or acceptance criteria
• Experience working in a high-volume manufacturing or fab environment and partnering with process, equipment, quality, and production teams
• Track record of owning complex, ambiguous materials problems end-to-end, setting priorities with limited supervision, and delivering results on tight timelines
• Experience mentoring engineers, technicians, interns, or new hires to a high-performing level
• Comfortable with data analysis (Python, JMP, MATLAB, or equivalent) to correlate process, metrology, and electrical results
• Strong first-principles problem solving and a demonstrated ability to dig deep on ambiguous materials and device-performance challenges
• Passion for building, learning quickly, and owning outcomes end-to-end; thrives in a fast-paced, scrappy environment with tight timelines
• Effective written and interpersonal communication skills; able to convey complex technical ideas, influence decisions, and drive alignment across teams
• 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