Lead Hardware Reliability Engineer (Starshield)

SpaceX•Hawthorne, CA

About The Position

SpaceX’s Starshield leverages Starlink technology and launch capability to support national security efforts. Designed for government use, Starshield initially focuses on earth observation, communications, and hosted payloads. This role will build and lead a hardware reliability team supporting Starshield production. The Lead Hardware Reliability Engineer identifies, analyzes, and resolves hardware and process failures to improve the robustness, yield, and documentation of Starshield subassemblies. The work spans PCBA production, battery builds, solar arrays, tanks, and mechanical assemblies such as actuators, reaction wheels, torque rods, and star trackers. The role partners with manufacturing, design, quality, and supply chain teams to strengthen build processes, improve first-pass yield, and lead containment when hardware or process issues put production at risk.

Requirements

Bachelor’s degree in mechanical engineering, electrical engineering, chemical engineering, process engineering, materials science, or another engineering discipline.
At least 3 years of experience in hardware development, manufacturing process engineering, failure analysis, or reliability engineering.
At least 1 year of experience leading a project, team, or people.
Able to work extended hours and weekends as needed.
Must meet U.S. export-control eligibility requirements: be a U.S. citizen or national, lawful permanent resident, refugee, or asylee, or be eligible to obtain required authorizations from the U.S. Department of State.

Nice To Haves

Strong analytical skills and excellent ability to communicate and collaborate with partners across disciplines and organizational levels.
Demonstrated ability to advocate for and implement robust, lasting solutions.
Experience deploying large-scale and/or high-impact solutions in a manufacturing environment.
Experience improving manufacturing processes, work instructions, and production documentation to increase yield and reduce defects.
Experience leading containment, material review, or nonconformance response for production hardware.
Hands-on experience with one or more of PCBA production, battery assembly, solar array manufacturing, pressure vessels or tanks, or electromechanical assemblies such as actuators, reaction wheels, torque rods, or star trackers.
Demonstrated experience troubleshooting and identifying root causes of hardware or process failures.
Experience with statistical process control, process capability analysis, yield analysis, and defect Pareto methods.
Familiarity with manufacturing process controls such as soldering, bonding, welding, torque, cleanliness, and leak or pressure testing.
Experience with environmental testing such as HALT/HASS, thermal, vibration, and TVAC.
Active Top Secret, Top Secret SCI, or DOE Level Q clearance, or the ability and willingness to obtain one.

Responsibilities

Lead and hire a team of hardware reliability engineers supporting Starshield production.
Provide technical mentorship and guidance to team members leading root cause investigations of subassembly and process failures.
Align goals and priorities with production and partner engineering teams to achieve program reliability, yield, and rate objectives.
Collaborate with team members to create personalized career growth plans that develop technical capabilities and support professional goals.
Drive data-informed improvements to products and processes that do not meet design or production requirements, using yield and defect monitoring to identify common failure modes.
Lead containment activities for nonconforming hardware, including isolating suspect product, assessing impact, and coordinating disposition and recovery.
Improve build processes, work instructions, and production documentation to reduce defects and increase first-pass yield across assigned subassemblies.
Lead qualification of production processes for assigned subassemblies and establish process readiness before rate production.
Lead PFMEA reviews with manufacturing and design partners to identify process risks, prioritize controls, and reduce risk.
Proactively escalate major hardware and process concerns, secure appropriate resources, and maintain clear communication to drive timely resolution and team alignment.
Maintain thorough documentation of failure analysis findings, process investigations, test results, and corrective actions.
Collaborate with the on-orbit reliability team and use on-orbit investigation findings to drive timely production improvements.

Benefits

Potential eligibility for long-term incentives in the form of company stock or long-term cash awards.
Potential discretionary bonuses.
Ability to purchase additional stock at a discount through an Employee Stock Purchase Plan.
Comprehensive medical coverage.
Vision coverage.
Dental coverage.
401(k) retirement plan.
Short- and long-term disability insurance.
Life insurance.
Paid parental leave.
Various other discounts and perks.
May accrue 3 weeks of paid vacation.
Eligible for 10 or more paid holidays per year.
Paid sick leave pursuant to Company policy.