Sr. Mechanical Engineer, Machine Design

About the role

You will join the Starship Tooling team to build the production infrastructure required for the Starship launch vehicle. This role is centered on the design, construction, and activation of custom machinery within our Starbase, Texas facility. The position requires ownership of end-to-end mechanical solutions that directly support vehicle production and handling operations. You will be responsible for creating robust factory systems that increase the speed and reliability of build and test processes for transport architectures. Collaboration with vehicle engineering teams is essential to refine manufacturing processes and influence vehicle designs iteratively. The role involves detailed structural sizing, mechanism design, and oversight of hardware fabrication activities. You will use advanced engineering models and technical prints to communicate designs and ensure alignment with production goals. Success in this position means enabling the scaling of production through precise machinery design and rigorous verification methods.

Key facts

What you'll do

• Create and activate custom hardware and infrastructure for Starship production and handling, ensuring systems are ready for operational use.
• Develop advanced factory systems to improve build and test speeds for transport architectures, focusing on throughput and reliability.
• Partner with vehicle engineering teams to optimize manufacturing processes and vehicle designs, providing mechanical insights during integration.
• Perform structural sizing, mechanism design, and hardware fabrication, applying rigorous engineering standards to every component.
• Generate engineering models and technical prints using NX, maintaining accurate documentation for fabrication and assembly instructions.
• Conduct engineering hand calculations to verify structural and mechanical integrity, validating digital models with analytical methods.
• Prepare manufacturing plans for internal welding and toolmaking departments, outlining precise steps and quality checkpoints.
• Coordinate with controls and production engineering teams during machine activation and testing to resolve issues quickly.
• Support the implementation of mass-efficient welded structures, emphasizing lightweight designs without compromising strength.
• Participate in mechanism design and testing, ensuring moving systems function reliably in high-stress production environments.
• Manage complex, large-scale CAD assemblies and drawings, maintaining clarity and consistency across multidisciplinary teams.
• Work within production environments with heavy machinery, adapting designs to practical constraints and real-world conditions.
• Collaborate effectively with technicians, suppliers, and leadership to align technical deliverables with project objectives.
• Drive continuous improvement in tooling and machinery, identifying opportunities to enhance efficiency and reduce downtime.

Requirements

• Bachelor degree in an engineering field, demonstrating foundational knowledge applicable to mechanical design challenges.
• 5+ years of professional experience in mechanical structure design and analysis, with a proven track record of success.
• Proficiency in CAD software such as NX, Solidworks, CATIA, or ProE, enabling detailed and accurate model development.
• Must be a U.S. citizen, lawful permanent resident, refugee, or asylee to comply with ITAR regulations governing sensitive technology.
• Strong understanding of structural analysis principles, ensuring designs meet safety and performance requirements.
• Experience with mechanism design and testing, including kinematics, dynamics, and failure mode assessment.
• Ability to manage complex, large-scale CAD assemblies and drawings, organizing intricate component relationships effectively.
• Willingness to work extended hours, weekends, and variable schedules based on site needs to meet critical project deadlines.

Nice to have

• 5+ years of technical project management experience, helping to lead cross-functional efforts and schedule adherence.
• Experience with finite element analysis, supporting detailed stress, strain, and displacement evaluations.
• Proficiency in GD&T application, ensuring clear and accurate geometric specifications on technical prints.
• Background in designing and fabricating mass-efficient welded structures, optimizing material use and performance.
• Experience with mechanism design and testing, including real-world validation and iterative improvements.
• Ability to manage complex, large-scale CAD assemblies and drawings, maintaining consistency across engineering domains.
• Experience working directly in production environments with heavy machinery, understanding operational constraints.
• Ability to collaborate effectively with technicians, suppliers, and leadership, fostering alignment and shared problem-solving.

Practical notes

• Must pass an Air Force background check for Cape Canaveral, ensuring compliance with security requirements.
• Requires physical ability to lift, stand, climb, bend, grasp, sit, pull, push, stoop, stretch, and carry as part of daily job activities.
• Expect to work extended hours, weekends, and variable schedules based on site needs to respond to production demands.
• Travel to other SpaceX sites may be required, supporting collaboration and knowledge transfer across locations.