Materials Engineer - Thin Films

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 Materials Engineer for thin films, you will partner with solar cell process engineering on PECVD-deposited films used in insourced cell manufacturing. You will characterize films, connect deposition conditions to material properties, support qualifications, and help lock in durable improvements to cell performance, yield, and cost. You will work problems of moderate to high complexity with guidance from more senior engineers and bring well-framed problems and proposed solutions to the team. 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), supporting materials characterization, film-property understanding, and production readiness
• Execute materials characterization and analysis of plasma-deposited films; correlate process conditions with thickness, refractive index, composition, lifetime, uniformity, and cell electrical/optical performance, and recommend next steps
• Build proficiency with thin-film materials, PECVD-relevant vacuum and plasma concepts, and lab/metrology methods; consult with senior engineers on higher-impact decisions while independently completing straightforward materials work
• Support DOEs and process trials: define materials measurements, collect high-quality data, and help interpret results with process engineering
• Support root cause analysis for film, interface, contamination, and yield issues: design experiments, execute failure analysis with characterization partners, and drive assigned corrective actions to completion with no loose ends
• Help define film material requirements, specifications, sampling plans, and acceptance criteria in partnership with process, quality, and production engineering
• Document materials results, specifications, and best practices; communicate status, risks, and recommendations clearly to cross-functional partners and, with support as needed, to leadership
• Identify opportunities to improve film materials performance, yield, cost, and manufacturability; raise issues early with proposed solutions rather than problems alone
• Support qualification of precursors, consumables, and film stacks, and production troubleshooting on the manufacturing floor; follow through until work is complete and understood
• Champion a culture of safety and quality in all vacuum, plasma, chemical/gas handling, lab, and production support activities

BASIC QUALIFICATIONS:

• Bachelor's degree in materials science, chemical engineering, electrical engineering, physics, or a STEM discipline
• 1+ years of professional experience with thin films, PECVD or vacuum-deposited coatings, or semiconductor/PV materials

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 deposition, film qualification, or production materials issues
• Familiarity with thin-film and solar-cell metrology such as spectroscopic ellipsometry, reflectance, FTIR, minority-carrier lifetime (QSSPC/PL), SEM-EDS, XPS, four-point probe, and optical inspection
• Working knowledge of film growth, precursor chemistry, plasma/vacuum processing, and how film properties couple to solar-cell passivation and optics
• Experience supporting structured root cause analysis (e.g., DOE, 5-why, fishbone) and converting findings into material or process recommendations
• Experience working in a high-volume manufacturing or fab environment and partnering with process, quality, and production teams
• 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 technical concepts across levels of the organization and ask for help early enough to still meet program needs
• Self-motivated with strong organizational skills, a bias toward action, and the ability to manage multiple projects with some prioritization support
• Demonstrated ability to perform short-term mentoring of interns or new hires

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, vacuum, and manufacturing environments, including work around pyrophoric, toxic, and flammable process gases