Sr. Mechanical Design Engineer, Consumer Hardware

About the role

This position focuses on the development of Starlink consumer hardware, ranging from initial concepts to large-scale manufacturing. You will create sophisticated, user-friendly equipment used by customers globally, including emergency responders and residential users in remote areas. The role requires a high level of ownership over the mechanical integrity and user experience of critical connectivity devices. You will act as a key technical leader in translating abstract requirements into robust physical products. Collaboration with cross-functional teams is central to navigating the constraints of production and usability. Success in this role means ensuring the hardware survives the realities of global deployment. You will be responsible for the design integrity from the first sketch to the final unit in the hands of a customer. This is a hands-on position that demands deep mechanical engineering judgment and practical problem-solving.

Key facts

What you'll do

• Orchestrate the full lifecycle of consumer hardware, maintaining strict ownership from the initial design phase through mass production ramp and public release.
• Conduct rigorous system-level optimizations to balance performance, reliability, and cost targets for the hardware portfolio.
• Define comprehensive design requirements and translate customer and regulatory needs into actionable mechanical specifications.
• Perform detailed product testing to validate reliability and performance across diverse environmental conditions encountered by end users.
• Engineer and refine production lines for your hardware, focusing on automation solutions, control systems, and robot end effectors.
• Drive continuous improvement in manufacturing processes to maximize yield, production rates, and overall equipment effectiveness.
• Partner with supply chain and internal stakeholders to balance trade-offs between quality, cost, and complexity during product integration.
• Lead root cause analysis for field failures and implement corrective actions to prevent recurrence in future production runs.
• Develop and maintain technical documentation and specifications that ensure consistency across global manufacturing sites.
• Mentor junior engineers on best practices for mechanical design, testing procedures, and manufacturing considerations.
• Ensure all designs comply with relevant safety standards, regulatory requirements, and internal quality benchmarks.
• Utilize advanced analysis methods to predict product behavior and guide material selection for durability and cost efficiency.

Requirements

• Hold a Bachelor degree in an engineering field, demonstrating a foundational understanding of mechanical principles.
• Possess a minimum of 5 years of professional experience in mechanical or electromechanical design, analysis, testing, or manufacturing.
• Demonstrate proficiency with CAD and FEA software tools to create and validate complex mechanical assemblies.
• Exhibit the ability to work extended hours and weekends to meet aggressive project deadlines without compromising quality.
• Show a strong commitment to adhering to safety protocols and regulatory compliance, particularly regarding ITAR restrictions.
• Be authorized to work in the United States without sponsorship, as this role requires U.S. citizenship or specific legal status.
• Apply meticulous attention to detail to ensure designs are manufacturable and meet stringent quality standards.
• Collaborate effectively within a fast-paced, matrixed team environment that values initiative and ownership.

Nice to have

• Hold a Master degree in engineering or a related technical discipline, providing deeper theoretical knowledge.
• Bring at least 3 years of professional experience in mechanical design and analysis, with a proven track record of success.
• Accumulate a minimum of 2 years of hands-on project experience with complex mechanical systems, ideally in a team lead capacity.
• Demonstrate expertise in 3D CAD, specifically NX, for advanced modeling and engineering workflows.
• Apply knowledge of GD&T, structural analysis, and failure mode assessment to create reliable and safe designs.
• Possess experience taking a complex assembly from design through high-volume production, understanding the challenges of scale.
• Show a strong understanding of design for manufacturability principles and various production equipment such as injection molders, die casters, motion systems, and industrial sensors.

Practical notes

• This role requires adherence to ITAR compliance: Applicants must be U.S. citizens, lawful permanent residents, refugees, or asylees.
• SpaceX is an Equal Opportunity Employer. Reasonable accommodations are available for the application process upon request.
• The position is located in Bastrop, Texas, and requires physical presence at the designated work site.
• Full-time engagement implies a standard schedule with the flexibility to work additional hours as project demands require.
• Travel may be required occasionally for team meetings, supplier visits, or product validation activities.
• Candidates must meet all legal work authorization requirements specific to the United States.
• The selection process may involve multiple interviews and assessments to ensure the best fit for the team.
• Successful candidates are expected to integrate quickly into the fast-paced culture of a growing space and technology company.