Materials Engineer, Metals

About the role

This position focuses on the materials engineering required for Starship and Super Heavy components. You will manage the development and testing of hardware such as valves, regulators, and actuators capable of operating in extreme thermal and pressure environments. The role requires deep engagement in defining the material and process requirements that ensure propulsion and mechanism systems perform reliably under mission-critical conditions. You will own the improvement of manufacturing reliability through strategic material selection and rigorous testing protocols. A core part of this position is establishing comprehensive thermal, physical, and mechanical property data for a wide range of materials used in flight hardware. You will conduct root cause analysis using metallography and fractography to drive corrective actions and prevent future failures. Providing technical guidance on engineering drawings and material specifications is essential to maintaining design integrity and compliance. You will collaborate closely with production and design teams to resolve material challenges and support rapid iteration in a high-stakes development environment.

Key facts

What you'll do

• Define material and process requirements for propulsion and mechanism systems to meet extreme operational demands.
• Improve manufacturing reliability through material selection and rigorous testing that de-risks production scaling.
• Establish thermal, physical, and mechanical property data for materials to support design allowables and analysis models.
• Conduct root cause analysis using metallography and fractography to identify failure origins and implement corrective actions.
• Provide technical guidance on engineering drawings and material specifications to ensure clarity and compliance across teams.
• Collaborate with production and design teams to resolve material challenges and optimize processes for quality and efficiency.
• Evaluate and qualify materials for fluid and gas compatibility within propulsion systems to prevent degradation and leaks.
• Support the development of non-destructive testing methods for fatigue and fracture control to verify integrity without damaging parts.
• Document test methods, results, and material certifications to maintain traceability and regulatory compliance.
• Advise on the selection of manufacturing processes such as forging, casting, and sheet/plate processing to meet performance targets.
• Assess the performance of tribological coatings and protective layers in space and atmospheric environments to extend component life.
• Partner with cross-functional teams to ensure materials meet NASA, ASTM, ASME, AWS, and NACE standards where applicable.

Requirements

• Bachelor degree in materials engineering or a related engineering field is mandatory for this role.
• Minimum 2 years of professional experience in materials engineering is required to ensure competency in core principles.
• Proficiency in at least two of the following processes: forging, casting, brazing, welding, heat treating, sheet/plate processing, or tribological coatings.
• Must meet ITAR requirements: U.S. citizen, lawful permanent resident, refugee, or asylee to access controlled technologies.
• Ability to work effectively in a fast-paced, high-priority environment where mission milestones drive deadlines.
• Willingness to adhere to strict engineering controls and documentation standards required for flight hardware.
• Understanding of the importance of mechanical testing in validating material performance under load and temperature extremes.
• Commitment to following regulatory standards such as NASA, ASTM, ASME, AWS, or NACE to ensure safety and reliability.

Nice to have

• Master degree or PhD in materials engineering provides advanced knowledge for complex material challenges.
• Experience with tribological processes and protective coatings for space or atmospheric environments is highly valued.
• Knowledge of nickel-based alloys, stainless steels, aluminum, and titanium supports material selection and qualification.
• Familiarity with failure analysis techniques like SEM, FTIR, and metallography enhances diagnostic capabilities.
• Understanding of design allowables and non-destructive testing for fatigue and fracture control is preferred for critical assessments.
• Experience with fluid and gas compatibility in propulsion systems supports integration and testing efforts.
• Background in manufacturing environments and regulatory standards like NASA, ASTM, ASME, AWS, or NACE is advantageous.

Practical notes

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Salary: Level I ($100,000 - $115,000) or Level II ($110,000 - $135,000).

• Compensation includes long-term incentives, stock options, discretionary bonuses, and an Employee Stock Purchase Plan.
• Benefits include medical, dental, vision, 401(k), life insurance, disability, parental leave, 3 weeks vacation, and 10+ holidays.
• Expect up to 10% domestic travel as part of project responsibilities and collaboration needs.
• Weekend and extended hours may be required for mission milestones to meet critical development timelines.