Solar Cell Reliability Engineer (Starlink)

SpaceX•Bastrop, TX

7d•Onsite

About The Position

SpaceX is seeking a Solar Cell Reliability Engineer for its Starlink program. This role will be responsible for the end-to-end reliability of heterojunction (HJT) solar cells used in spacecraft and constellation assets. The engineer will own the reliability lab, define and execute test matrices, build reliability narratives for reviews, and collaborate with process and equipment engineers to link process parameters to reliability outcomes. The goal is to ensure solar cells deliver unmatched power density and durability for various SpaceX missions, contributing to the Starlink network's success and global internet provision. The role involves leading root cause analysis, defining reliability KPIs, interfacing with other engineering teams, supporting anomaly investigations, and mentoring junior staff.

Requirements

Bachelor’s degree in an engineering discipline
1+ years of experience in chemical engineering, materials science, electrical engineering, physics, or mechanical engineering in design, analysis, and/or system implementation (internship and extracurricular experience is applicable)

Nice To Haves

Master’s degree or Ph.D. in chemistry, chemical engineering, materials science, environmental, or related technical discipline (especially in PV, thin-film devices, reliability physics, or space power systems)
2+ years of hands-on experience in solar cell, PV module, semiconductor device, or aerospace hardware reliability (internship/co-op experience may count toward this if highly relevant and hands-on)
Experience designing, running, or analyzing accelerated environmental or reliability tests and interpreting degradation / failure data
Proficiency with data analysis (e.g., Python, MATLAB, JMP, R, or equivalent) and comfort with statistics (distributions, confidence bounds, DOE basics)
Ability to work full-time on-site in a production and lab environment
Strong understanding of vacuum systems, plasma physics, sputtering dynamics, and thin-film characterization techniques (e.g., XRD, SEM, Hall effect)
Hands-on experience with PV metrology tools (eg. Sinton lifetime, EL/PL) and reliability testing
Experience with SPC, DoE, and lean manufacturing principles
Self-motivated with strong organizational, written, and oral communication skills
Experience with solar cell manufacturing equipment, such as wet chemical processing equipment, PE-CVD equipment, PVD machines, metallization and final test equipment, and wafer inspection equipment. Experience in evaporation tools and ALD tools are a plus

Responsibilities

Own and operate the solar cell reliability lab: equipment strategy, capability roadmap, calibration, maintenance, safety, throughput, and data integrity for HJT cell and coupon reliability testing
Define, execute, and continuously improve the space reliability test matrix for HJT solar cells (e.g., thermal cycling, thermal vacuum, humidity/damp heat as applicable, UV/photo-stability, reverse bias / hotspot, mechanical shock/vibration at cell/coupon level, radiation exposure coordination, and accelerated life tests)
Build and own the reliability narrative for flight and program reviews: failure modes, physics of failure, acceleration models, life predictions, margins, and acceptance/qualification logic that ties lab data to on-orbit performance
Partner with HJT process and equipment engineering (texturing, PECVD/a-Si stacks, TCO, metallization, module integration) to link process parameters, metrology, and in-line defects to reliability outcomes; drive corrective actions and design-for-reliability changes
Establish reliability gates for process changes, tool qualifications, material substitutions, and supplier changes; own risk assessment (FMEA/PFMEA interfaces), sampling plans, and release criteria
Develop and maintain test methods, SOPs, fixturing, and automation for high-throughput, statistically defensible reliability characterization; ensure methods are transferable and auditable
Lead root cause analysis on reliability failures (electrical, optical, interfacial, mechanical, environmental) using SEM/FIB, EDS, FTIR, PL/EL, IV, quantum efficiency, adhesion, and other failure-analysis techniques; close the loop with manufacturing and design
Define and track reliability KPIs (e.g., degradation rates, wear-out distributions, infant mortality, lot-to-lot variation, correlation of accelerated tests to flight-like stress) and report status to leadership with clear recommendations
Interface with power systems, structures, thermal, radiation effects, quality, and flight reliability teams so cell-level reliability is coherent with array/module and spacecraft environments
Support flight anomaly investigation and on-orbit performance trending; update models and test strategies as flight data matures.
Mentor technicians and junior engineers; set lab culture for rigor, speed, and honest interpretation of data
Author and present technical content for design reviews, production readiness reviews, and customer/internal reliability packages as required