Process Safety Engineer

About the role

SpaceX is seeking a Process Safety Engineer to define human safety standards for the Raptor engine and Starship programs. You will join the Environmental Health and Safety team to manage risk and ensure operational safety during the development of colonization-class launch vehicles. The role requires ownership of safety-critical processes and the implementation of robust controls to protect personnel and equipment. You will drive the integration of safety protocols across manufacturing and test environments to support high-risk operations. This position is critical in ensuring compliance with functional safety requirements for complex engineering systems. The successful candidate will act as a key advisor on safety matters influencing system design and test execution. You will contribute to building a scalable safety framework that supports rapid iteration and production efficiency.

Key facts

What you'll do

• Develop safety protocols and tools to improve production planning and efficiency, aligning workflow with critical safety parameters.
• Evaluate industrial machinery risks and design functional safety systems including SIL and SIS to meet stringent reliability targets.
• Act as the Laser Safety Officer for the department, enforcing controls and monitoring exposure levels for personnel.
• Execute PFMEAs to maintain manufacturing safety by identifying potential failure modes and implementing corrective actions.
• Review ground support equipment and tooling for load factors and safety compliance to verify structural integrity under operational conditions.
• Advise on high-pressure system designs and participate in test readiness reviews to ensure safe validation procedures.
• Collaborate with engineering teams to integrate safety controls within robotic and automated manufacturing processes.
• Analyze incident trends and near-miss data to refine safety metrics and improve preventive measures across facilities.
• Support the development of standard operating procedures for handling hazardous materials and pressurized systems.
• Partner with cross-functional teams to align safety requirements with program schedules and performance objectives.

Requirements

• Bachelor degree in aerospace, mechanical, materials, manufacturing, electrical, or a related STEM field.
• Minimum 1 year of experience in design, quality, or manufacturing engineering, including internships or academic project teams.
• Must meet ITAR requirements: U.S. citizen, lawful permanent resident, refugee, or asylee.
• Ability to obtain and maintain a security clearance as required by the position and project needs.
• Willingness to work in a high-risk environment where safety protocols must be strictly followed at all times.
• Physical ability to perform essential job functions, including prolonged periods of standing, walking, and inspecting equipment.
• Compliance with all company policies, safety regulations, and environmental standards governing workplace conduct.
• Willingness to relocate to the assigned work location as required for the duration of the engagement.

Nice to have

• Master degree in electrical, mechanical, aerospace, or materials engineering.
• Proficiency in lean principles, root cause analysis, statistical process control, APQP, metrology, and design of experiments.
• Experience with Python, MySQL, R, Tableau, JMP, Minitab, and Ignition.
• CAD skills in NX, Solidworks, Catia, or Creo.
• Background in Robotic Process Automation and Ansys for CFD or CAE.
• Specialized knowledge in chemical delivery systems, pressure systems, and process safety management.

Skills & tools

• PFMEA
• Functional safety (SIS, SIL)
• High pressure systems
• Safety code review

Practical notes

• This role requires on-site work in Hawthorne, CA, with occasional weekend or extended hours. Relocation is required if not local.

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Salary: Level I $95,000 to $115,000; Level II $110,000 to $130,000 per year.

• Total rewards include potential stock options, long-term cash awards, discretionary bonuses, and an Employee Stock Purchase Plan.
• Benefits include medical, dental, vision, 401(k), life insurance, disability insurance, paid parental leave, 3 weeks of vacation, and 10+ holidays.
• New hires must complete all onboarding documentation and background checks prior to starting employment.
• Employment is contingent upon verification of credentials and eligibility to work in the assigned location.