Lead Mechanical Engineer, Hardware Reliability

About the role

This position oversees the reliability of Starlink hardware throughout its entire lifecycle, from the factory floor to field deployment. You will manage a team focused on reducing hardware failures and customer downtime while reporting findings to senior leadership.

Key facts

What you'll do

• Mentor and lead a team of engineers and specialists dedicated to the reliability of Starlink user terminals, Wi-Fi routers, power supplies, and cables.
• Direct resources toward new product qualification, production priorities, and field investigations to ensure rapid troubleshooting.
• Partner with design, software, manufacturing, and supply chain teams to influence product development and maximize hardware performance.
• Execute root cause investigations for production and field failures, driving corrective actions to mitigate future risks.
• Design and perform environmental, mechanical, electrical, and RF reliability tests tailored to specific failure mechanisms.
• Automate test execution and data analysis to improve decision-making speed and repeatability.
• Monitor field performance metrics, such as return rates, to identify and address systemic product issues.
• Manage production quality processes, including material review boards, defect tracking, and compliance with ISO 9001 standards.
• Analyze telemetry, logs, and physical PCBA hardware to resolve issues with phased-array and power systems.

Requirements

• Bachelor degree in electrical, mechanical, materials, manufacturing, or aerospace engineering.
• 2+ years of experience in design qualification, manufacturing, hardware reliability, or production environments.
• 1+ years of experience in a leadership role managing a team of at least 3 engineers.

Nice to have

• Master degree in electrical, mechanical, materials, manufacturing, or aerospace engineering.
• Experience creating product qualification strategies and defining acceptance criteria.
• Proficiency in reliability engineering principles, failure mechanisms, and risk-based decision-making.
• Background in high-volume manufacturing and transitioning hardware into mass production.
• Familiarity with PCB, PCBA, and electromechanical assembly systems.
• Knowledge of Wi-Fi standards and network operations.

Skills & tools

• Reliability testing (environmental, mechanical, electrical, RF)
• Root cause analysis and corrective action (CAPA)
• Data visualization and test automation
• ISO 9001 quality systems
• Telemetry and log analysis
• PCBA and electromechanical debugging