Process Engineer, PCB Reliability (Starlink)

PROCESS ENGINEER, PCB RELIABILITY (STARLINK)

SpaceX is leveraging our experience building rockets and spacecraft to deploy Starlink, the world’s largest satellite constellation and most advanced broadband internet system. We provide reliable and fast internet to millions of users worldwide, including populations with little or no connectivity, rural communities, aircraft, watercraft, and places where existing services are unreliable, too expensive, or disconnected by natural disasters. We design, build, test, and operate all parts of the system, thousands of satellites and consumer antennae that allow users to connect within minutes of unboxing. The Starlink team is seeking out the best-in-class professionals to maximize Starlink’s potential for communities and businesses around the globe.

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.

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

BASIC QUALIFICATIONS:

• 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)

PREFERRED SKILLS AND EXPERIENCE:

• 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