Sr. Device Physics Engineer, Solar Cells (Starlink)

SpaceX•Bastrop, TX

About The Position

SpaceX is seeking a Sr. Device Physics Engineer to lead end-to-end cell efficiency ownership in its high-volume silicon heterojunction (SHJ) solar cell fab for Starlink. The role integrates specialized process and equipment engineering work to maximize cell performance, define wafer specifications, design space-optimized cell architectures, and establish metrology and reliability frameworks. Work spans ingot growth, wafer preparation, deposition, passivation, metallization, testing, and module fabrication to support solar cells for Starship, Starlink, AI satellites, and deep-space missions. The engineer will lead production-process development and help establish a greenfield solar cell production plant, including equipment and laboratory procurement, plant design and layout, equipment commissioning and ramp-up, recipe and process development, and development of a high-performing production team. The role is accountable for production outcomes across yield, uptime, and cost, and for scaling lab- and pilot-level processes to production.

Requirements

Bachelor’s degree in an engineering discipline.
5+ years of experience in chemical engineering design, analysis, and/or system implementation.
Ability to travel frequently for work, potentially for extended periods during machine buyoffs and startup.
Ability to lift 25 lbs. unassisted.
Must be willing to work extended hours and weekends as needed.
Must meet the stated U.S. export-control eligibility requirements or be eligible to obtain the required authorizations.

Nice To Haves

Master’s degree or Ph.D. in chemistry, chemical engineering, materials science, environmental, or another STEM discipline.
Strong understanding of vacuum systems, plasma physics, sputtering dynamics, and thin-film characterization techniques such as XRD, SEM, and Hall effect.
7+ years of experience in solar cell physics, device modeling, or PV process integration; experience with SHJ, PERC, TOPCon, or HJT is preferred.
Deep understanding of SHJ efficiency drivers, including surface passivation, carrier selectivity, TCO optics, and space degradation mechanisms.
Hands-on experience with PV metrology tools such as Sinton lifetime and EL/PL, and with reliability testing.
Proficiency in PV simulation software and statistical data analysis; scripting experience with Python, R, or SQL and experience with tools such as SIMTRA for sputtering.
Expertise in advanced SHJ topics such as poly-Si contacts, bifacial optimization, or perovskite tandems for greater-than-30% targets.
Strong publication record in PV conferences or journals and experience leading multidisciplinary teams.
Experience with SPC, DOE, and lean manufacturing principles.
Ability to work in a cleanroom environment.
Hands-on experience with complex fluid- or mechanical-based production systems in a professional setting.
Experience transitioning products from design to manufacturing and scaling to high volume as part of a cross-functional team.
Experience with solar cell manufacturing equipment, including wet chemical processing, PE-CVD, PVD, metallization, final test, and wafer inspection equipment; evaporation and ALD tool experience is a plus.
Experience with microstructure analysis tools such as SEM, TEM, EDX, and SIMS, and optical/electrical characterization tools such as UV-VIS, I-V, and resistance measurement.
Experience in cost-of-ownership modeling, CapEx justification, and fab ramp-ups to multi-GW scales.
Passion for sustainable energy and space technology; prior GW-scale photovoltaics work is a plus.

Responsibilities

Own the end-to-end cell efficiency roadmap by integrating processes across ingot growth, wafer preparation, deposition, passivation, metallization, and testing.
Define and qualify incoming wafer specifications for SHJ compatibility, partnering with suppliers and internal supply teams.
Design and iterate SHJ cell architectures optimized for space applications, including radiation tolerance, thermal-vacuum cycling, UV exposure, and high specific power.
Develop a fab-wide metrology strategy, including selecting, commissioning, and calibrating inline and offline tools for process control and yield correlation.
Lead reliability engineering by establishing accelerated life testing labs, defining qualification protocols, and predicting mission lifetimes.
Build and maintain physics-based models for loss analysis and guide design of experiments with process teams.
Analyze production data to identify efficiency limiters, lead cross-functional improvements, and support fab ramps.
Mentor team members on photovoltaic physics and represent solar cell performance in spacecraft power-system design reviews.
Develop, implement, and maintain manufacturing processes, equipment, technologies, and facilities.
Analyze production processes and machinery using first-principles, physics-based approaches.
Develop experiments using robust DOE and statistical methods to diagnose and correct manufacturing problems.
Optimize process conditions and materials to improve the optical and electrical quality of solar cells.
Develop project plans, budgets, and cost-benefit analyses for new processes or machines.
Prepare detailed technical design review content.
Take ownership of the solar factory’s production outcomes across yield, uptime, and cost.
Scale lab- and pilot-level processes to production in close collaboration with the process engineering team.