Sr. PVD Process Engineer, Solar Cells

About the role

SpaceX is on a mission to establish a specialized facility for solar cell production, aimed at powering Starlink satellites as well as future missions involving the Starship to the Moon and Mars. In this pivotal position, you will oversee the entire lifecycle of a new manufacturing plant, which includes everything from the procurement of equipment and the design of the layout to the ramp-up of full-scale production.

Key facts

What you'll do

• Develop and refine DC and RF magnetron sputtering processes for both the front and back contacts of silicon heterojunction (SHJ) solar cells.
• Oversee the acquisition, installation, and commissioning of new production equipment to ensure operational readiness.
• Utilize physics-based analysis techniques to identify and resolve manufacturing bottlenecks, thereby enhancing cell efficiency.
• Conduct experiments employing statistical methods to improve both electrical and optical quality of solar cells.
• Perform thorough root cause analyses on defects to implement strategies for yield enhancement.
• Prepare project budgets, cost-benefit analyses, and detailed technical design documentation.
• Lead a team of engineers and technicians through the commissioning of machinery and the scaling of production to high volumes.
• Collaborate with cross-functional teams to ensure alignment on project goals and timelines, facilitating a smooth transition from development to production.
• Monitor and report on production metrics, making data-driven decisions to optimize processes.
• Stay updated on industry trends and advancements in solar technology to continuously improve production techniques.
• Train and mentor junior engineers and technicians, fostering a culture of continuous learning and improvement.
• Ensure compliance with safety and environmental regulations throughout all phases of production.

Requirements

• A bachelor's degree in an engineering discipline is required.
• A minimum of 5 years of relevant professional experience in chemical engineering design, system implementation, or analysis is essential.
• Must be capable of lifting up to 25 lbs and performing physical tasks that include climbing, bending, and standing for extended periods.
• Willingness to travel frequently for equipment buyoffs and the initiation of facility operations is necessary.
• Availability to work extended hours and weekends as needed to meet project deadlines.
• Must meet ITAR requirements, which include being a U.S. citizen, lawful permanent resident, refugee, or asylee.

Nice to have

• A master's degree or Ph.D. in chemistry, materials science, chemical engineering, or a related STEM field is preferred.
• At least 7 years of experience in PVD process engineering within the display, semiconductor, or thin-film solar manufacturing sectors is advantageous.
• Proven experience in scaling PVD processes to production volumes exceeding 1GW annually is a plus.
• Familiarity with SHJ-specific processes, including low-temperature ITO deposition, is highly desirable.
• Proficiency in programming languages such as Python, R, SQL, or experience with simulation tools like SIMTRA is beneficial.
• Experience with perovskite tandem solar cells would be an asset.
• Knowledge of micro-structural characterization tools, including SEM, TEM, EDX, SIMS, XRD, and Hall effect measurements, is a plus.

Skills & tools

• Expertise in vacuum systems, plasma physics, and sputtering dynamics is crucial.
• Familiarity with Statistical Process Control (SPC), Design of Experiments (DoE), and lean manufacturing principles is essential.
• Experience with solar manufacturing equipment such as PE-CVD, wet chemical processing, metallization, and wafer inspection is required.
• Ability to conduct cost of ownership modeling and provide justifications for capital expenditures (CapEx) is necessary.

Practical notes

SpaceX is committed to fostering a diverse and inclusive workplace. We are an equal opportunity employer and welcome applications from all qualified individuals. If you require reasonable accommodations during the application process or would like to view our Affirmative Action Plan, please reach out to EEOCompliance@spacex.com.

About the company

Based in Starbase, Texas, a company pursues work in spaceflight, telecom, and artificial intelligence. A unit handles rocket launches, leading yearly orbital counts beyond other national and commercial teams. Another unit runs Starlink, a satellite communications firm. A third area, through SpaceXAI, advances Grok and AI integration with X, while managing data center operations. Roles often cross these paths. Candidates with engineering, software, or operations backgrounds may find chances to join projects that span launch, connectivity, and machine learning efforts in this Texas-based enterprise.