Sr. Materials Engineer, Blades and Vanes Foundry

About the role

The successful candidate will join the Materials Engineering team to advance high-volume Starship production through innovative foundry operations and process optimization. You will own the technical execution of material solutions for critical gas turbine components made from nickel-superalloy castings. This role requires deep collaboration with design, operations, and supply chain to resolve issues that directly impact production yield and reliability. You will drive the development of single crystal, directionally solidified, and equiaxed cast components from laboratory scale to high-volume manufacturing. The position demands rigorous root cause analysis and data-driven decisions to improve yields, reduce scrap, and ensure consistent material performance. You will translate complex failure mechanisms into actionable process changes that align with manufacturing constraints and cost targets. This is a hands-on leadership role where your technical guidance will define the standards for alloy selection, tooling, and process specifications.

Key facts

What you'll do

Accelerate the development and production of single crystal (SX), directionally solidified (DS), and equiaxed (EQ) cast components for gas turbines through systematic experimentation and process refinement.

Develop, qualify, and troubleshoot metal casting processes by designing trials, analyzing results, and implementing corrective actions that scale to production volumes.

Conduct failure analysis on cast components to improve yields, working alongside design and process engineers to identify contributing factors and permanent solutions.

Perform root cause investigations using metallography, fractography, and advanced characterization techniques to correlate processing conditions with material behavior.

Provide technical guidance on alloy selection, tooling design, and process specifications to ensure robustness, repeatability, and compliance with aerospace standards.

Design and execute qualification test plans for castings and foundry processes, defining acceptance criteria, test methods, and validation protocols.

Coordinate with operations, supply chain, vendors, and leadership to maintain alignment on performance, cost, and delivery timelines while managing technical risks.

Optimize designs based on manufacturability, efficiency, cycle time, and product lifespan to enable high-volume production without compromising integrity or performance.

Leverage digital tools and data analytics to monitor in-process variables, detect trends, and predict potential defects before they result in scrap or field failures.

Champion continuous improvement by documenting best practices, updating technical work instructions, and sharing knowledge across cross-functional teams.

Support new product introductions by translating customer requirements into material and process solutions that meet performance, certification, and cost objectives.

Act as a technical subject matter expert during design reviews, risk assessments, and problem-solving sessions to ensure materials requirements are addressed early.

Promote safety and quality culture by adhering to strict procedures, escalating non-conformances, and driving corrective actions to prevent recurrence.

Represent the materials engineering function in interactions with external vendors and partners to ensure alignment with SpaceX standards and expectations.

Requirements

Bachelor degree in materials science, materials engineering, weld engineering, metallurgical engineering, or related engineering field.

5+ years of professional experience in metal casting technologies with a demonstrated track record of delivering production-ready solutions.

Must meet ITAR requirements: U.S. citizen, national, lawful permanent resident (green card holder), refugee, or asylee.

Ability to obtain and maintain a U.S. government security clearance, which requires eligibility for U.S. citizenship as defined by ITAR regulations.

Willingness to comply with SpaceX policies, including but not limited to substance abuse testing, background checks, and security protocols.

Physical ability to perform essential job functions, including but not limited to lifting up to 30 lbs, standing, and walking for extended periods.

Acceptance of an at-will employment arrangement that may involve adjustments to roles, responsibilities, or work assignments based on business needs.

Commitment to working extended hours and weekends as required to meet manufacturing and testing schedules without compromising safety or quality.

Nice to have

Master degree or Ph.D. in materials science, materials engineering, weld engineering, metallurgical engineering, or equivalent combination of education and experience.

5+ years of experience with SX or DS casting technologies using Ni-based superalloys in demanding aerospace or industrial gas turbine environments.

Experience casting blades and vanes for aerospace engines or industrial gas turbines, with a strong understanding of airfoil geometry and cooling requirements.

3+ years of experience with metallographic characterization equipment and techniques, including SEM-EDS, optical microscopy, hardness testing, mechanical property testing, or spectroscopy.

Hands-on experience in high-production manufacturing environments, including familiarity with statistical process control, sampling plans, and quality metrics.

First principles understanding of how process variables such as temperature, atmosphere, cooling rate, and melt chemistry affect material performance, fatigue, and fracture behavior.

Proven ability to work effectively in fast-paced, deadline-driven settings where prioritization, adaptability, and clear communication are essential.

Experience with failure analysis methodologies such as fractography, root cause analysis, and corrective and preventive action (CAPA) processes.

Familiarity with aerospace quality standards, Nadcap requirements, and regulatory expectations related to castings and material traceability.

Practical notes

Ability to lift up to 30 lbs unassisted.

Must be able to stand or walk for extended periods.

Willingness to travel up to 15% to vendor sites or other SpaceX locations as required for technical support or qualification activities.

Expect to work long hours and weekends as needed to support manufacturing and testing schedules, with compensation handled in accordance with company policies and legal guidelines.

Employment is contingent upon satisfaction of applicable background checks, security clearance eligibility, and adherence to SpaceX employment conditions.

This role is based in Bastrop, Texas, and requires relocation or local availability to perform the essential functions of the position on-site.