Materials Engineer, Welding

About the role

This position focuses on the development and manufacturing of Starship components, including regulators, actuators, and valves. You will lead efforts to refine welding processes for hardware that operates in extreme environments ranging from 80 to 800K and pressures exceeding 800 bar.

Key facts

What you'll do

• Develop, optimize, and qualify welding parameters for various techniques including electron beam, laser beam, gas tungsten arc, orbital tube, resistance, and gas metal arc welding.
• Provide technical guidance to production staff and welders to ensure high-quality output in a fast-paced manufacturing setting.
• Conduct root cause analysis and collaborate with design, tooling, and automation teams to improve welded assemblies.
• Design qualification test campaigns and analyze mechanical testing and NDE results.
• Implement automated welding solutions and evaluate new technologies to improve efficiency and consistency.
• Partner with NDE personnel to interpret weld quality and develop advanced inspection techniques.

Requirements

• Bachelor degree in an engineering field.
• Practical experience in fabrication, manufacturing, or testing of welded assemblies.
• Ability to work extended hours and weekends as required.
• Ability to travel up to 25 percent of the time.
• Must meet ITAR requirements: U.S. citizen, lawful permanent resident, refugee, or asylee.

Nice to have

• Advanced degree in welding engineering, material science, mechanical engineering, aerospace engineering, or physics.
• Expertise in laser, electron beam, OTW, GTAW, and GMAW processes, specifically with nickel alloys and stainless steel.
• Experience with CNC or robot programming for welding automation.
• Background in tooling design to minimize distortion and increase consistency.
• Knowledge of weld strength testing standards such as ASTM E8, E399, E740, ISO 15653, AWS D17.X, and AWS C7.X.
• Proficiency in root cause analysis using SEM fractography, metallography, hardness testing, and chemical analysis.

Skills & tools

• Welding processes: Electron beam, laser beam, GTAW, OTW, resistance, GMAW, plasma arc.
• Testing: NDE, mechanical testing, strain gages, thermocouples.
• Analysis: SEM fractography, metallography, hardness testing, chemical analysis.
• Automation: CNC and robot programming.

Practical notes

• Salary range: Level 1 ($100,000 to $117,500) or Level 2 ($115,000 to $140,000).
• Compensation includes potential stock options, long-term cash awards, and discretionary bonuses.
• Benefits include medical, dental, and vision coverage, 401(k), life insurance, disability insurance, and paid parental leave.
• Vacation policy includes 3 weeks of paid leave plus 10 or more paid holidays annually.