Lead Hardware Reliability Engineer (Starshield)

SpaceX•Hawthorne, CA

1d•$155,000 - $215,000

About The Position

Starshield leverages SpaceX’s Starlink technology and launch capability to support national security efforts, with an initial focus on earth observation, communications, and hosted payloads. The Lead Hardware Reliability Engineer will build and lead a hardware reliability team supporting Starshield production. The role identifies, analyzes, and resolves hardware and process failures to improve robustness, yield, and documentation across subassemblies. Work spans PCBA production, battery builds, solar arrays, tanks, and mechanical assemblies such as actuators, reaction wheels, torque rods, and star trackers. The engineer 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 the stated U.S. Government export-control eligibility requirements or be eligible to obtain required authorizations.

Nice To Haves

Strong analytical skills and excellent ability to communicate and collaborate with partners in all disciplines and at multiple 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 finding 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 on personalized career growth plans that build technical capabilities and advance professional goals.
Use data-driven decisions and yield and defect monitoring to identify common failure modes and improve products and processes that do not meet design or production requirements.
Lead containment for nonconforming hardware, including suspect-product isolation, impact assessment, and coordination of 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 drive risk reduction.
Escalate major hardware and process concerns, secure appropriate resources, and maintain clear communication to drive timely resolution and team alignment.
Document failure-analysis findings, process investigations, test results, and corrective actions thoroughly.
Collaborate with the on-orbit reliability team and drive timely production improvements based on on-orbit investigation findings.

Benefits

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