Process Engineer, PCB Reliability (Starlink)

SpaceX • Bastrop, TX

2d

About The Position

As a Process Engineer on our Hardware Reliability team, you will contribute to Starlink's in-house printed circuit board (PCB) production line—the largest in North America—by supporting quality and reliability efforts from material selection through end-user performance. You will assist with quality escalations, participate in new product and process qualifications, conduct root cause investigations, and collaborate with cross-functional teams to help ensure our PCBs deliver the highest standards of reliability for Starlink user terminals, satellites, and other hardware. In this role, you'll gain hands-on experience applying industry-standard methods for PCB reliability while learning physics-of-failure analysis to support the most reliable hardware possible.

Requirements

• Bachelor's degree in materials science, chemical engineering, electrical engineering, physics, or other applied engineering discipline
• 1+ years of experience with hardware development or electronics test engineering (internship and extracurricular experience is applicable)

Nice To Haves

• Master's degree in a relevant field or hands-on projects/internships focused on PCB reliability, electronics manufacturing, or failure analysis
• Familiarity with IPC or similar test standards for PCBs (e.g., thermal shock, flexure, or solderability methods)
• Understanding of core physics-of-failure concepts for common PCB issues (e.g., delamination, cracking, or via reliability)
• Hands-on experience or coursework with reliability testing, environmental chambers, data analysis tools, or lab equipment (e.g., inspection techniques)
• Knowledge of additional standards such as IPC-6012, MIL-STD-810, or testing methods like HALT/HASS
• Experience with scripting (e.g., Python) for data processing or test automation
• Background in NPI, supplier support, or volume production environments
• Familiarity with failure analysis tools (e.g., X-ray, cross-sectioning, SEM, electrical test)
• Familiarity with root-cause investigations, data analysis, and experimental methods
• Strong analytical, problem-solving, and hands-on skills with a desire to learn reliability engineering practices
• Ability to thrive in a fast-paced, hands-on environment with a passion for innovation and SpaceX's mission

Responsibilities

• Collaborate with design, manufacturing, supply chain, and engineering teams to verify that PCBs satisfy mission profile requirements for space and terrestrial environments
• Conduct root cause investigations for reliability and quality escalations using physics-of-failure approaches to identify and address failure mechanisms
• Execute environmental, mechanical, and electrical testing for new PCB designs and materials in alignment with IPC standards
• Collect and analyze test data from accelerated life testing (e.g., thermal cycling, vibration, humidity) to support reliability assessments and modeling
• Develop and establish quality standards and procedures through data analysis, metric tracking, and validation testing
• Contribute to process improvements, corrective actions, and yield enhancement initiatives based on failure analysis findings to aid high-volume manufacturing
• Document results, support metric tracking, and present findings to help inform team decisions and risk mitigation

What This Job Offers

• Job Type: Full-time
• Career Level: Entry Level