Sr. Mechanical Design Engineer, Satellites

About the role

Become a vital member of the Starlink Production Design team, where your expertise will contribute to the development of manufacturing systems for the high-volume production of satellites and ground stations. In this role, you will be responsible for designing specialized tooling, machinery, and automation systems, overseeing projects from their inception through to fabrication and deployment, all within a rapid timeline that emphasizes efficiency and innovation.

Key facts

What you'll do

• Design and develop structures, mechanisms, and automation tools that facilitate the mass production of Starlink satellites.
• Assume complete responsibility for projects throughout their entire lifecycle, from initial concept development to fabrication and scaling up production.
• Juggle multiple projects simultaneously, each varying in scope and complexity, while thriving in a dynamic and fast-paced environment.
• Work closely with both flight design and production teams to simultaneously advance the development of satellites, factory systems, and manufacturing processes.
• Address complex engineering challenges with a strong emphasis on speed and operational efficiency.
• Collaborate with internal teams and external suppliers, ensuring that project schedules and budgets are adhered to.
• Personally build and commission the equipment that you design, ensuring that it meets all operational requirements.
• Engage in continuous improvement initiatives, identifying opportunities to enhance production processes and tooling designs.

Requirements

• A Bachelor's degree in an engineering discipline is required.
• At least 5 years of hands-on experience in mechanical engineering is essential.
• Proficient in designing mechanical systems using 3D CAD software and creating 2D drawings.
• Willingness to work extended hours and weekends as needed to meet project deadlines.
• Strong problem-solving skills and the ability to work independently as well as part of a team.
• Excellent communication skills to effectively convey technical information to diverse audiences.

Nice to have

• Experience in structural design and analysis is a plus.
• Familiarity with custom machine design, particularly with electromechanical systems, motors, actuators, linear rails, bearings, and lifting/rigging.
• Capability to perform structural hand calculations to validate design integrity.
• Knowledge of design for manufacturability and design for assembly principles, especially in transitioning products from development to high-volume production.
• Understanding of drafting standards and the application of GD&T (Geometric Dimensioning and Tolerancing).
• Experience with common manufacturing processes and equipment, including manual and CNC mills and lathes, along with practical machining experience.
• Proficiency in Siemens Unigraphics (UGS/NX) and Teamcenter CAD/PDM systems.
• Familiarity with finite element analysis (FEA) tools such as FEMAP, NASTRAN Solver, ANSYS Workbench, or NX Advanced Simulation.
• Background in manufacturing process development, including facility and line layouts, process failure mode effects analysis, and error-proofing methodologies.

Skills & tools

• Proficient in 3D CAD software and the creation of 2D drawings.
• Experience with Siemens Unigraphics (UGS/NX) for design purposes.
• Familiarity with Teamcenter for product data management (PDM).
• Competence in using FEA tools like FEMAP, NASTRAN, ANSYS Workbench, and NX Advanced Simulation for structural analysis.

Practical notes

• Salary range: $130,000 to $180,000 annually, based on relevant knowledge, skills, education, and experience.
• Eligible for long-term incentives, including company stock or cash awards, discretionary bonuses, and discounted stock purchases through the Employee Stock Purchase Plan.
• Comprehensive benefits package including medical, vision, and dental insurance.
• Access to a 401(k) retirement savings plan.
• Short-term and long-term disability insurance, along with life insurance coverage.
• Paid parental leave policy.
• Accrual of three weeks of paid vacation and ten or more paid holidays each year.
• Paid sick leave in accordance with Washington State laws.
• Company-provided shuttles for commuting from select locations in Seattle to the Redmond office, available Monday through Friday.
• ITAR compliance: Applicants must be U.S. citizens, lawful permanent residents, refugees, asylees, or eligible to obtain the necessary U.S. Department of State authorizations.