Sr. Materials Engineer, Silicon Wafer Engineering

About the role

This position serves as the primary technical authority for the production of silicon wafers dedicated to Starlink solar cells, a critical component enabling global broadband connectivity. The hire will own the end-to-end qualification, implementation, and oversight of space-grade reliability standards for wafer manufacturing processes. You will direct the selection, setup, and validation of equipment used for wafer slicing, cleaning, degumming, and final inspection to ensure process robustness. Collaboration with solar engineering, production, and supply chain teams will define and lock wafer specifications that balance performance, cost, and manufacturability. A core responsibility is managing the qualification of all wafer processing steps, including ingot cropping, surface conditioning, and contamination control measures. You will establish rigorous inspection protocols, metrology strategies, and environmental controls to maintain a stable and high-yield production environment. The role requires linking metrology and defect data directly to device electrical performance to develop clear, actionable acceptance criteria for wafers. You will perform detailed root-cause analysis to drive continuous improvement, reduce defects, and optimize processes for scalability and reliability.

Key facts

What you'll do

• Direct the selection, installation, and validation of equipment for wafer slicing, cleaning, degumming, and inspection to ensure process reliability.
• Partner with solar engineering, production, and supply chain to define, document, and approve wafer specifications that meet performance and manufacturing targets.
• Manage the qualification of all wafer processes, including ingot cropping, surface preparation, conditioning, and final inspection routines.
• Approve supplier materials such as slurries, wires, and chemicals, conducting thorough assessments to prevent contamination and ensure compliance.
• Establish and implement inspection protocols, metrology strategies, and environmental controls to monitor critical process parameters.
• Link metrology data, defect maps, and electrical test results to define and refine acceptance criteria for wafers used in solar cell production.
• Perform root-cause analysis of yield-limiting defects and drive corrective actions to optimize processes for throughput and reliability.
• Assist in factory layout and workflow planning to support efficient scale-up to high-volume manufacturing while maintaining quality.
• Mentor junior materials engineers and provide expert technical guidance to cross-functional teams on wafer processing and failure analysis.
• Lead cross-functional initiatives to resolve complex manufacturing issues, ensuring alignment on technical objectives and timely execution.
• Develop and maintain material qualification standards, test methods, and documentation to support production releases and audits.
• Collaborate with reliability and test engineering teams to validate long-term durability and performance under space-relevant conditions.
• Track and analyze process metrics to identify trends, drive improvements, and reduce variability in wafer quality and performance.
• Support the development of automated data systems for real-time monitoring and control of critical wafer manufacturing steps.

Requirements

• Hold a Bachelor degree in materials science or chemical engineering from an accredited institution.
• Possess 5+ years of professional experience in semiconductor processing or wafer manufacturing, with a focus on process engineering.
• Demonstrate a strong understanding of silicon materials science, including crystal growth, defect types, and their impact on device performance.
• Have hands-on experience with wafer slicing, cleaning, and surface preparation techniques, including the use of slurries, wires, and chemicals.
• Show proven ability to work within strict quality, safety, and contamination control standards in a high-precision manufacturing environment.
• Exhibit strong analytical skills to interpret metrology data, correlate process inputs with output performance, and drive problem-solving.
• Possess excellent written and verbal communication skills to effectively collaborate with cross-functional teams and document technical decisions.
• Be capable of working independently and managing multiple priorities in a fast-paced, deadline-driven environment.

Nice to have

• Hold a Master degree or PhD in materials science, chemical engineering, or a related field with a focus on silicon or solid-state materials.
• Bring 8+ years of hands-on experience in silicon wafer manufacturing, specifically in photovoltaics or compound semiconductor environments.
• Demonstrate deep expertise in silicon materials science, surface chemistry, defect mechanisms, and fracture mechanics relevant to wafer processing.
• Show proficiency with silicon ingot slicing equipment, including scribing, sawing, and grinding tools, and associated consumables.
• Have direct experience scaling manufacturing processes from R&D or pilot stages to high-volume production with yield optimization.
• Possess strong knowledge of statistical process control, design of experiments, and yield analysis techniques to drive process improvements.
• Exhibit a proven track record of leading cross-functional teams to achieve shared technical objectives and resolve complex issues.
• Have experience implementing and maintaining material specifications, supplier qualification programs, and continuous improvement initiatives.

Skills & tools

• Hands-on experience with characterization equipment and techniques, including ICP-MS, TXRF, SIMS, FTIR, GC-MS, SEM, resistivity mapping, and minority carrier lifetime testing (PL).
• Ability to interpret data from these tools to diagnose material defects and guide process adjustments.
• Familiarity with documentation, reporting, and data analysis tools used in a regulated manufacturing environment.

Practical notes

• Must be a U.S. citizen, lawful permanent resident, refugee, or asylee to comply with ITAR regulations.
• Ability to travel up to 25% of the time for supplier visits, technical reviews, or meetings as required.
• Must be available for extended hours and weekends as needed to support production schedules and urgent technical issues.
• Work environment involves exposure to noise, odors, and fumes, with occasional work in confined spaces during equipment maintenance or inspections.