Sr. Materials Engineer, Metals

About the role

Join the Starbase team to advance the Starship project and support the goal of making human life multiplanetary. This role operates at the heart of an intense development environment where material performance dictates mission success. You will own the deep technical investigation of metallic components driving the next generation of launch systems. The position requires high-level ownership of complex material challenges in a remote operational setting. You will act as a critical link between laboratory data and flight hardware decisions. Success in this role means ensuring that material choices are robust, reliable, and executable under demanding conditions. You will directly influence the manufacturability and performance of the vehicle through your expertise in metals. This is a hands-on role that blends analysis with practical implementation to solve immediate production and design issues.

Key facts

What you'll do

• Trace the complete history and performance of materials from initial concept validation through to flight acceptance.
• Extract and define thermal, mechanical, and physical properties for a diverse range of metallic materials under varying conditions.
• Execute root cause analysis using metallography, fractography, and rigorous testing methodologies to identify failure origins.
• Drive improvements in design and manufacturing reliability by translating test data into actionable process changes.
• Liaise closely with flight hardware engineers to verify and ensure the correct material application in line with engineering specifications.
• Partner directly with technicians and subject matter experts to troubleshoot and resolve intricate processing and material challenges.
• Evaluate and recommend material solutions that balance performance requirements with manufacturability and cost constraints.
• Develop and maintain detailed documentation of material properties, test procedures, and analysis results for engineering records.
• Support the qualification and certification of new materials for aerospace applications through comprehensive testing and analysis.
• Implement and monitor material inspection techniques to maintain high standards of quality control on the production floor.
• Analyze test results to refine material selection and processing parameters for optimal durability and reliability.
• Collaborate with cross-functional teams to integrate material insights into the broader development and production workflow.

Requirements

• Hold a Bachelor degree in materials engineering or materials science from an accredited institution.
• Possess a minimum of 5 years of professional, research, or internship experience focused on metallics in a materials engineering capacity.
• Demonstrate eligibility to obtain a U.S. government security clearance, requiring U.S. citizenship.
• Comply with ITAR regulations, necessitating status as a U.S. citizen, lawful permanent resident, refugee, or asylee.
• Show the ability to work effectively in a high-paced, remote site environment demanding extended hours.
• Commit to a work schedule that includes availability for extended hours and weekends as dictated by project urgency.
• Accept the requirement for occasional travel to other SpaceX sites in Florida or California for project support.
• Adhere to the strict safety protocols inherent in a rocket manufacturing and testing environment.
• Maintain a high degree of personal accountability for the accuracy and reliability of material analysis.

Nice to have

• Hold a Master degree or PhD in materials science or engineering, indicating advanced specialized knowledge.
• Bring 10 or more years of professional experience in materials engineering, with a strong track record of independent problem-solving.
• Show proficiency in failure analysis, metallographic analysis, and characterization techniques using equipment like the Scanning Electron Microscope (SEM).
• Possess deep experience with aerospace metals, specifically titanium, aluminum, stainless steel, and nickel-based alloys.
• Demonstrate familiarity with design allowables and standard material testing methods used in the aerospace industry.
• Have a background in mechanical testing for metals and hands-on experience in a manufacturing setting.
• Exhibit a proven ability to solve problems quickly, efficiently, and with a high standard of technical accuracy.

Skills & tools

• Apply expertise in metallography to prepare and examine metallic samples for microstructural analysis.
• Utilize fractography techniques to investigate fracture surfaces and determine failure mechanisms.
• Operate a Scanning Electron Microscope (SEM) to perform detailed material characterization and imaging.
• Conduct mechanical testing, including tensile, hardness, and impact tests, to validate material properties.
• Draw on in-depth aerospace alloy knowledge to select materials suitable for extreme environments.

Practical notes

• Must be a U.S. citizen, lawful permanent resident, refugee, or asylee to comply with ITAR requirements.
• Expect to work extended hours and weekends as required by project demands.
• Occasional travel to Florida or California sites may be necessary.
• SpaceX is an Equal Opportunity Employer.