Principal Solar Process Engineer

The Role

The processes that go into developing K2's solar arrays — from module interconnects and adhesive systems to cover glass coatings and substrate composites — directly determine how much power they produce, how long they last, and how fast we can build them. Getting the process engineering right is not a support function here; it is on the critical path.

You will define how K2 selects, qualifies, and scales manufacturing processes for its solar array systems. The operating environments, mission lifetimes, and production rates we are pursuing demand meaningful impact in how our materials are characterized, qualified, and manufactured. You will own the success of implementation of material systems and novel manufacturing processes in the development and scaling of K2’s solar array design and production.

Responsibilities

• Responsible for the development, qualification, and production-scale optimization of K2’s solar array processes — including solar module interconnects, bonding, sintering, lamination, deposition, coating, bonding, mechanism joints, and surface treatment

• Research, evaluate, and select conventional and novel processes for solar array applications, driving trades that balance performance, manufacturability, cost, reliability, and schedule

• Design and execution of structured DOE and statistical analyses to diagnose manufacturing problems and validate corrective actions

• Use a first-principle, physics-based characterization across production processes to identify sources of variation and opportunities for yield improvement

• Lead failure analysis, defect characterization, and root causes investigations for process related anomalies

• Establish and drive corrective action plans back into design requirements and production

• Own the evaluation, cost/benefit analysis, and selection of manufacturing equipment for all in-house process development

• Collaborate with the production team to develop process specifications, work instructions, in-process checkouts, and end-of-line tests

• Define qualification criteria, test envelopes, and characterization campaigns to establish resultant performance across radiation, thermal cycling, mechanical, and plasma environments

• Partner with solar structures/mechanisms, thermal, avionics, and production teams to define manufacturing process-driven requirements, integrated qualification/acceptance testing, and on-orbit data review

• Collaborate with leadership on staffing plans, role definitions, and recruiting efforts to ensure the solar array team is appropriately staffed to meet system deliverables

• Mentor engineers and establish institutional process knowledge and best practices for solar array hardware at production scale

Qualifications

• Bachelor's degree in materials science, chemical engineering, mechanical engineering, physics, aerospace engineering, or a related technical discipline

• 8+ years of experience in materials and process engineering, with demonstrated depth in material selection, characterization, qualification, and production-scale process development

• Demonstrated track record of material and process decisions that have been validated through flight or equivalent high-reliability hardware programs

Nice to Have

• Master's degree or PhD in materials science, chemical engineering, or a related field

• Prior experience architecting manufacturing processes for solar array systems across the full development lifecycle — requirements definition, trade studies, development testing, qualification, production, and on-orbit data review

• Hands-on experience across multiple solar array material systems, with variation in cell technology, interconnect methodology, encapsulant chemistry, and system architecture

• Deep working knowledge of adhesive systems, composites, thin films, thermal interface materials, and coatings as applied to high-power, long-life solar array hardware

• Working knowledge of AIAA S111/S112, SMC-S-016, NASA-STD-4005, NASA-STD-5017, and NASA-STD-6016 for solar module qualification, materials usage, and spacecraft charging effects

• Understanding of radiation effects on solar cell and module materials — displacement damage dose modeling, ionizing effects, UV degradation, and atomic oxygen erosion

• Depth across solar process disciplines including deposition techniques for anti-reflective coatings, chemical etching for bond preparation, encapsulant deposition, methods for corrosion control, outgassing compatibility, descriptive and inferential statistics, and failure analysis.

• Hands-on proficiency with material characterization tools: SEM, EDS, FTIR, DSC, TGA, XRD, or equivalent

• Experience scaling manufacturing processes from prototype to high-rate production, including SPC implementation and manufacturing equipment qualification

• Python or MATLAB proficiency for test data analysis and degradation modeling

Compensation and Benefits:

• Base salary range for this role is $175,000 - $200,000 + equity in the company

• Salary will be based on several factors including, but not limited to: knowledge and skills, education, and experience level

• Comprehensive benefits package including paid time off, medical/dental/vision coverage, life insurance, paid parental leave, and many other perks