Build Engineer, COPVS

About the role

In this role, you will play a vital part in the production and qualification of composite overwrapped pressure vessels (COPVs) utilized in the Starship and Super Heavy Booster programs. Your responsibilities will encompass hardware design, the development of manufacturing processes, and facilitating the transition from prototype stages to high-volume production. This position requires a blend of practical engineering skills and analytical problem-solving abilities to ensure that production timelines are met effectively.

Key facts

What you'll do

• Collaborate closely with vehicle analysts to ensure that manufacturing solutions align with the requirements of flight hardware.
• Develop and refine production procedures, facilitating the transition of parts and assemblies from the development phase into large-scale manufacturing.
• Plan and execute development, qualification, and acceptance tests for various systems and tooling.
• Implement design-for-manufacturability enhancements aimed at increasing production efficiency.
• Create CAD models and detailed drawings for flight components and associated tooling.
• Take ownership of design engineering decisions on-site during the assembly and part-building processes.
• Develop and maintain comprehensive build schedules to track progress and ensure timely completion.
• Work alongside quality teams to investigate manufacturing discrepancies and identify corrective actions.
• Participate in both internal and external design reviews, engaging with suppliers and customers to ensure alignment.
• Collaborate with engineering and production teams to identify and implement improvements for both current and future vehicle designs.
• Assess and provide technical guidance to vendors to ensure quality and compatibility with project requirements.

Requirements

• A bachelor's degree in mechanical or aerospace engineering is required.
• At least one year of engineering experience in a manufacturing or production environment is necessary (internships and academic projects are acceptable).
• Willingness to work extended hours and weekends as required by site operations.
• Physical requirements include standing for up to 3 hours a day, sitting for up to 6 hours a day, lifting up to 25 lbs without assistance, pushing or pulling up to 50 lbs without assistance, overhead reaching for up to 3 hours a day, walking for up to 3 hours a day, and climbing ladders or stairs for up to 1 hour a day.

Nice to have

• A master's degree in mechanical, manufacturing, aerospace, materials, or industrial engineering is preferred.
• Involvement in a professional engineering society or participation in collegiate design projects is a plus.
• Practical experience in building, assembling, or integrating large mechanical systems is advantageous.
• Familiarity with composite manufacturing processes, including resin curing, cylinder cleaning and inspection, and pressurized testing is beneficial.
• Knowledge of metallic manufacturing techniques such as welding, metal forming, fastening, drilling, bonding, and automation is a plus.
• Experience in mechanical component or tooling design and analysis using 3D CAD software is desirable.
• A background in design for manufacture and assembly (DFMA) is advantageous.
• Proven experience in transitioning complex products from research and development to high-volume production in a fast-paced environment is a plus.
• Experience in writing work instructions and procedures for critical aerospace components is beneficial.
• Previous work experience in aerospace production settings is a plus.

Skills & tools

• Proficiency in 3D CAD modeling and the creation of detailed drawings.
• Experience with mechanical testing and the development of welding processes.
• Knowledge of inspection techniques and tooling design.
• Skills in production scheduling and discrepancy analysis.

Practical notes

• Salary range for Level 1 positions is between $100,000 and $117,500; for Level 2 positions, it ranges from $115,000 to $140,000. Actual salary and level will depend on your knowledge, skills, education, and experience.
• Total rewards include company stock or long-term cash incentives, potential discretionary bonuses, and a discount on the Employee Stock Purchase Plan.
• Benefits include comprehensive medical, vision, and dental coverage; a 401(k) plan; short and long-term disability insurance; life insurance; paid parental leave; three weeks of paid vacation accrual; more than ten paid holidays annually; and paid sick leave according to company policy.
• ITAR compliance: Applicants must be U.S. citizens, U.S. nationals, lawful permanent residents, refugees under 8 U.S.C. 1157, asylees under 8 U.S.C. 1158, or eligible to obtain the necessary U.S. Department of State authorizations.
• For accommodation requests, please contact EEOCompliance@spacex.com.