Supplier Development Engineer, Assembly Process (Starlink)

SUPPLIER DEVELOPMENT ENGINEER, ASSEMBLY PROCESS (STARLINK)

SpaceX is developing a low latency, broadband internet system to meet the needs of consumers across the globe. Enabled by a constellation of low Earth orbit satellites, Starlink will provide fast, reliable internet to populations with little or no connectivity, including those in rural communities and places where existing services are too expensive or unreliable. We are looking for talented, creative, and driven engineers to develop, drive, and maintain suppliers, from initial concept development to full scale production.

The role entails early engagement in global supplier selection, equipment selection, and process engineering to set programs up for success in high-volume manufacturing by ensuring material and process corners are fully completed. The role also includes ownership to deliver on time, monitor field performance, react to issues, and feed lessons learned back to engineering teams for iterative improvement. This position demands deep manufacturing process expertise and extreme ownership from early design selection through process characterization, line qualification, and field performance feedback.

RESPONSIBILITIES:

• 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
• 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
• Perform reactive quality engineering support, including rapid containment, root cause analysis using eight disciplines (8D) and five-whys (5-Why) methodologies, and corrective actions for quality escapes, field returns, and production issues
• Own on-time delivery of process qualification and production ramp activities while continuously monitoring field performance, reacting quickly to issues, and feeding lessons learned from field data back to design and process engineering teams for iterative improvement

BASIC QUALIFICATIONS:

• Bachelor’s degree in mechanical, electrical, or mechatronics engineering (or relevant disciplines)
• 3+ years of high-volume process development experience for consumer electronics or complex hardware manufacturing

PREFERRED SKILLS AND EXPERIENCE:

• Master's degree or PhD in mechanical, electrical or mechatronics engineering (or relevant disciplines)
• 10+ years of high-volume process development experience with mechanical assemblies or relevant electronics hardware.
• Strong technical background in ultrasonic welding, hot plate welding, vibration welding, precision dispensing, and automated optical inspection
• Hands-on experience bringing up and qualifying ultrasonic welding, hot plate welding, vibration welding, and heat staking processes in high-volume production environments
• Deep expertise in thermal interface material (TIM) and sealant dispensing, including viscosity control, dispense valve technology, and closed-loop feedback systems
• Strong experience developing automated optical inspection (AOI) systems, including illumination optimization, image processing, and defect classification algorithms
• Expertise in statistical methods including design of experiments (DOE), statistical process control (SPC), process capability analysis (Cp/Cpk), and measurement system analysis (MSA)
• Experience leading full line qualification (IQ/OQ/PQ) and production part approval process (PPAP) at contract manufacturers
• Knowledge of relevant standards including IPC-A-610, IPC-J-STD-001, ISO 9001, and AS9100
• Strong problem-solving skills using structured root cause analysis methods and statistical tools such as Minitab and design of experiments (DOE)
• Excellent written and verbal communication skills with the ability to distill complex technical topics into clear one-pagers, process characterization reports, and executive presentations
• Demonstrated ability to influence cross-functional teams and contract manufacturers in a fast-paced, high-growth environment

ADDITIONAL REQUIREMENTS:

• Position is based in Bangalore, India and requires being onsite - remote work not considered
• Must be willing to work long hours and weekends when needed to meet critical deadlines
• Ability to travel: Up to 30% of work week travel may be required to suppliers in Southeast Asia