The opportunity
SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.
What you'll do
Own end-to-end process development, equipment bring-up, and qualification for: precision assembly technologies at contract manufacturers, spanning strategic supplier selection, new product introduction (NPI), and high-volume production
Engage early with suppliers on equipment selection, tooling design, and: process engineering to properly set up high-volume manufacturing programs by ensuring material and process corners are fully characterized and completed
Lead development of ultrasonic welding processes, including amplitude, force,: energy, weld time, and trigger optimization, as well as horn design, joint geometry, and weld strength validation for both metal and thermoplastic components
Develop hot plate welding and vibration welding processes for plastic: housings and enclosures, focusing on temperature uniformity, platen design, melt displacement control, weld pressure profiles, and long-term joint durability
Optimize heat staking and hot riveting processes for plastic boss forming,: including temperature control, pressure profiling, staking tool design, and dimensional stability validation
Develop and qualify precision dispense processes for thermal interface: materials (TIM), adhesives, and sealants, including rheological characterization, volumetric vs. time-pressure dispensing, needle selection, vision-guided positioning, and repeatable bead or dot formation
What they're looking for
- Establish and optimize automated optical inspection (AOI) systems, including: multi-angle lighting techniques, high-resolution imaging, algorithm development, false call reduction, and integration with deep learning-based defect detection
- Design and execute comprehensive design of experiments (DOE) and corner case: studies (material and process windows) to define robust parameter ranges and ensure process capability across environmental and material variations
- Lead line qualification activities at contract manufacturers, including: equipment installation qualification (IQ), operational qualification (OQ), performance qualification (PQ), gauge repeatability and reproducibility (GR&R), and production part approval process (PPAP)
- Develop detailed process control plans, failure mode and effects analysis: (FMEA), statistical process control (SPC) limits, and reaction plans to sustain high process capability in mass production
