Sr. PCB Designer (Starship)

About the role

Become a vital member of the Starship electronics team, where you will be responsible for designing printed circuit board (PCB) layouts for some of the most sophisticated flight hardware in the aerospace sector. This role involves close collaboration with hardware development engineers, guiding projects from the initial schematic phase through to design evaluations. You will face a variety of challenges, including the design of radio phased arrays and power converters, requiring quick thinking and innovative solutions in a fast-paced environment.

Key facts

What you'll do

• Develop and define layer stack-ups, choose component packages, and conduct feasibility studies for placement and routing across various types of boards, including digital, analog, RF, and power conversion.
• Create multilayer layouts (20+ layers) that incorporate high-speed routing techniques, differential pairs, length matching, and controlled impedance, as well as design for power and ground planes.
• Perform pre-layout and post-layout signal integrity (SI) and power integrity (PI) simulations to mitigate issues related to crosstalk, reflections, and electromagnetic interference (EMI) or electromagnetic compatibility (EMC).
• Conduct design rule checks (DRC), electrical rule checks (ERC), peer evaluations, and design audits, while also supporting prototype bring-up in collaboration with hardware and firmware engineers.
• Produce fabrication deliverables such as Gerber files, ODB++, IPC-2581 files, drill files, stack-up drawings, and assembly documentation.
• Assess designs for manufacturability and integrate feedback from fabrication and assembly partners to enhance cost efficiency and yield rates.
• Collaborate with both internal teams and external PCB manufacturers to refine design rules, constraints, and guidelines for design for test (DFT) and design for manufacturability (DFM).
• Create and validate symbols, footprints, and 3D models; work with librarians to introduce new components and resolve library-related issues.
• Work alongside mechanical, thermal, RF, and test engineers to plan stack-ups, thermal vias, shielding, and ensure proper enclosure fit.
• Contribute to the development of a roadmap for custom AI tools aimed at enhancing the efficiency of PCB design processes.

Requirements

• A minimum of 5 years of professional experience in PCB layout design is required.

Nice to have

• Over 5 years of experience with modern passive and active components, surface-mount technology, RF components, BGA, and other high-density packages.
• At least 2 years of experience managing ECAD libraries and their configurations.
• A strong understanding of principles related to design for manufacturability, assembly, and testing.
• Practical experience with Mentor Xpedition (preferred) and/or Altium Designer.
• Background in mixed analog/digital layouts, high-speed buses, FPGA, DRAM, CPU designs, power supplies, DC-DC converters, transmission lines, and impedance-controlled traces.
• Proficiency in generating fabrication outputs (Gerber, ODB++, IPC-2581, drill files), conducting DFM/DFA reviews, and executing constraint-driven designs.
• Excellent spatial reasoning skills for effective component placement and interconnect planning.
• Familiarity with scripting in Python or using Altium/Mentor Xpedition scripting languages to automate library tasks, data extraction, and validation processes.
• Experience coordinating cross-functional projects and collaborating with various engineering disciplines.
• Ability to thrive in a dynamic, self-directed startup environment.
• Strong written and verbal communication skills are essential.

Skills & tools

• Proficient in Mentor Xpedition and Altium Designer.
• Familiarity with signal integrity (SI) and power integrity (PI) simulation tools.
• Experience with generating outputs such as Gerber, ODB++, and IPC-2581 files.
• Competence in Python scripting for automation purposes.
• Knowledge of ECAD library management practices.

Practical notes

• Be prepared for extended hours and potential weekend work during critical project phases and mission deadlines.
• Salary range: $130,000 to $180,000 annually; the actual offer will be based on relevant experience, skills, and educational background.
• Total compensation may also include company stock, stock options, long-term cash incentives, discretionary bonuses, and eligibility for the Employee Stock Purchase Plan.
• Benefits package includes medical, vision, and dental insurance, a 401(k) plan, short and long-term disability coverage, life insurance, paid parental leave, 3 weeks of paid vacation, over 10 paid holidays annually, and paid sick leave in accordance with company policy.
• ITAR compliance: Candidates must be U.S. citizens, U.S. nationals, lawful permanent residents (green card holders), refugees under 8 U.S.C. 1157, asylees under 8 U.S.C. 1158, or otherwise eligible to obtain the necessary authorization from the U.S. Department of State.