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Aerospace, Space Exploration, Telecommunications, Manufacturing

Materials Engineer, Solar Cell Characterization

Bastrop, TXInternshipEntry-level (exp-based)Posted 2 months ago

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Required skills

solar cell characterization
metrology
materials characterization
failure analysis
root cause analysis
process engineering
quality engineering
production engineering
semiconductor
PV metrology

Nice to have

photovoltaic devices
silicon wafers
thin films
semiconductor devices
I-V
Suns-Voc

Role summary

Starlink is insourcing solar cell manufacturing and seeks a Materials Engineer for solar cell characterization. This role will own offline metrology and materials characterization, developing measurement capabilities and analysis methods to improve cell performance and yield. Responsibilities include leading root cause analysis for performance and yield excursions, defining measurement requirements, qualifying metrology tools, and translating characterization results into actionable recommendations. The engineer will partner with process, production, and quality teams to implement durable fixes and improve manufacturability. This role requires a Bachelor's degree in a technical discipline and 1+ years of relevant experience, with a strong foundation in materials science and characterization techniques.

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.

MATERIALS ENGINEER, SOLAR CELL CHARACTERIZATION

Starlink is building the world's largest satellite constellation to deliver fast, reliable internet to people who need it most—and powering that constellation starts on the factory floor. We are insourcing solar cell manufacturing end-to-end, from crystal growth and ingot production through wafering and cell fabrication, to drive performance, cost, and scale at every step. High-efficiency, high-reliability cells made in-house are the backbone of the Starlink network: more photons in means more data out to customers around the world.

As a Materials Engineer for solar cell characterization, you will own offline metrology and materials characterization of insourced solar cells—building the measurement capability, analysis methods, and physical understanding needed to raise cell performance and yield. You will turn electrical, optical, and materials data into root cause, and interface with process, production, and quality teams to lock in durable fixes. If you are passionate about solving hard problems, anchor your engineering judgment with first-principles thinking, and are relentless about acting with urgency, this role is for you.

RESPONSIBILITIES:

Own characterization and metrology strategy for insourced solar cells across cell interfaces—from method development and tool qualification through production-ready measurement recipes

Build and maintain a suite of offline electrical, optical, and materials characterization techniques to quantify cell performance, reliability, and yield-limiting defects (e.g., I-V, quantum efficiency, PL/EL imaging, lifetime, SEM-EDS, optical microscopy, spectroscopy, and related methods)

Lead root cause analysis for performance and yield excursions: design experiments, execute failure analysis, correlate process history with metrology signatures, and drive corrective actions to first principles

Define measurement requirements, sampling plans, gauge R&R, calibration, and acceptance criteria in partnership with process, quality, and production engineering

Stand up and develop processes for offline metrology equipment; own data integrity, tool matching, and measurement uncertainty so results can be trusted for process decisions

Translate characterization results into clear material and process recommendations that improve efficiency, reliability, cost, and manufacturability

Partner with process engineering on DOEs and golden-line development; provide rapid feedback loops during recipe, materials, and equipment changes

Document methods, specifications, FA reports, and best practices; communicate status, risks, and recommendations clearly to cross-functional partners and leadership

Champion a culture of safety and quality in all sample preparation, chemical handling, lab operations, and production support activities

BASIC QUALIFICATIONS:

Bachelor's degree in materials science, materials engineering, chemical engineering, or a related technical discipline

1+ years of professional experience in materials characterization, failure analysis, semiconductor/PV metrology, or a related laboratory or manufacturing role (internship and co-op experience applicable)

PREFERRED SKILLS AND EXPERIENCE:

Master's degree or PhD in materials science, materials engineering, chemical engineering, or a related technical discipline

Hands-on experience characterizing photovoltaic devices, silicon wafers, thin films, or semiconductor devices

Proficiency with solar cell and wafer metrology such as I-V, Suns-Voc, EQE/IQE, photoluminescence, electroluminescence, minority-carrier lifetime (QSSPC/PL), ellipsometry, four-point probe, and optical inspection

Experience with materials analysis techniques including SEM-EDS, FIB cross-sectioning, AFM, XRD, FTIR, XPS, SIMS, ICP-MS, and optical microscopy

Experience designing and implementing a laboratory inventory management system (including architecture, workflows, and user access), building automated pipelines to transfer metrology data from tools into the LIMS, and integrating SPC (control charts, dashboards, and alerts) on the collected data

Demonstrated ability to lead structured root cause analysis (e.g., DOE, 5-why, fishbone, fault-tree) and convert findings into process or material improvements

Experience qualifying metrology tools, writing measurement SOPs, and establishing statistical process controls or gauge capabilities

Experience working in a high-volume manufacturing or fab environment and partnering with process, quality, and production teams

Strong first-principles problem solving and a demonstrated ability to dig deep on ambiguous materials and device-performance challenges

Comfortable with data analysis (Python, JMP, MATLAB, or equivalent) to correlate metrology, process, and electrical results

Passion for building, learning quickly, and owning outcomes end-to-end; thrives in a fast-paced environment with tight timelines

Effective written and verbal communication skills; able to convey technical concepts across all levels of the organization

Self-motivated with strong organizational skills and a bias toward action

ADDITIONAL REQUIREMENTS:

Willingness to travel to other SpaceX sites and/or vendors as needed (up to 25%)

Ability to lift up to 25 lbs unassisted

Ability to stand/walk for extended periods in the lab and on the manufacturing floor

Willingness to work extended hours and weekends as needed to support manufacturing, tool bring-up, and critical milestones

Must be able to wear appropriate PPE for lab and manufacturing environments

ITAR REQUIREMENTS:

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.

SpaceX is an Equal Opportunity Employer; employment with SpaceX is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Applicants wishing to view a copy of SpaceX’s Affirmative Action Plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to EEOCompliance@spacex.com.

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