Sr. Process Controls Engineer, Solar Cell Factory (Starlink)

Bastrop, Texas, United StatesOnsiteFull TimeSeniorPosted 2 months agoVisa sponsorship available

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Role summary

SpaceX is seeking a Sr. Process Controls Engineer for its Starlink solar cell factory. This role focuses on designing, building, and optimizing controls and automation systems for critical gas and chemical delivery in solar cell fabrication. The engineer will program PLCs, develop SCADA systems, select and integrate instrumentation, and ensure compliance with safety standards (SIL, ATEX, EPA/NPDES, NEC, NFPA, UL508A). Responsibilities include commissioning, testing, troubleshooting, and root-cause analysis to support 24/7 operations. The ideal candidate has 5+ years of experience in fluids/systems manufacturing, controls, and automation, with expertise in hazardous material handling and industrial electrical systems.

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.

SR. PROCESS CONTROLS ENGINEER, SOLAR CELL FACTORY (STARLINK)

The Solar Cell team is revolutionizing power generation for space applications through advanced solar cell manufacturing. We're scaling production of high-efficiency solar cells to support sustainable energy solutions for Starlink constellations, launch vehicles, and beyond. As a Sr. Process Controls Engineer, you will design, build, and optimize controls and automation systems for the delivery of critical gases and chemicals in solar cell fabrication. This role requires a detail-oriented engineer passionate about safe handling of hazardous materials in a high-volume manufacturing environment, ensuring reliable control code and safe instrumentation and design of processes like vacuum deposition and etching while minimizing risks and maximizing efficiency in our cutting-edge solar cell factory.

RESPONSIBILITIES:

Design, implement, and maintain automation systems including PLC programming and SCADA development for gas farm operations (e.g., vaporizers, storage, and transfer systems) and wastewater treatment processes (e.g., solids separation, clarification, and chemical dosing) to ensure safe, efficient, and compliant performance

Develop and program PLC control logic, PID loops, and interlocks for centralized control of distributed subsystems, optimizing for real-time monitoring of parameters such as pressure, temperature, flow, pH, and effluent quality

Select, calibrate, and integrate field instrumentation (e.g., transmitters, sensors, analyzers) in hazardous environments, ensuring compatibility with safety standards like SIL, ATEX, and EPA/NPDES regulations

Lead commissioning, FAT/SAT testing, and troubleshooting of control systems, performing root-cause analysis to minimize downtime and support 24/7 operations with rapid alarm response

Design electrical systems compliant to NEC, NFPA, & UL508A regulations

BASIC QUALIFICATIONS:

Bachelor's degree in engineering, physics, or chemical discipline

5+ years of experience with fluids/systems manufacturing, controls and automation, and/or programming

PREFERRED SKILLS AND EXPERIENCE:

Excited by a quick and iterative design and manufacturing role

Proven ability to solve complex problems with simple solutions in both design and implementation stages

Excellent communication skills both written and verbal, with the ability to make plans and directional recommendations collaboratively and cross-functionally

Ability to engineer creative, new approaches to problems while adhering to ANSI/RIA15.06/OSHA safety requirements to keep a factory safe

Hazardous process expertise in an aerospace, oil and gas, or chemical industry where high pressure or hazardous systems for fluids or gasses were in use

Experience with at least one of the specific disciplines listed below. The ideal candidate is interested in learning at least the fundamentals of the other areas they are not yet strong in.

Electrical/Industrial Controls:

Electrical sizing of motors, valves, pneumatics, cables, circuit protection, VFDs, motor starters, various other motion systems

Design of fail-safe electrical circuits using both safety logic controllers and safety-rated relays

Hands-on experience troubleshooting industrial electrical systems using tools like multimeters, oscilloscopes, EMI probes

Proficiency in understanding and creating electrical schematics and single line diagrams (EPLAN preferred)

Field bus networks, serial communication, Profinet and Ethernet communications

Hands-on experience designing and commissioning high quality electrical panels and electro-mechanical systems with appropriate safety considerations in mind

Knowledge of NEC, NFPA, UL508A codes with ability to ensure compliance with control system safety standards

Industrial Software:

PLC programming, preferably Siemens TIA Portal structured text + ladder

HMI, SCADA, IoT (MQTT, OPC-UA), ignition systems with focus on user friendly navigation and machine health monitoring and control

Field Bus Networking protocols, preferably EtherCAT, Profinet, Profisafe, Ethernet/IP

Robotics programming, preferably ABB

Industrial software application to mechanical assemblies, electrical systems, sensors, pneumatics/hydraulics, including how to safely checkout these interdisciplinary systems prior to production implementation

ADDITIONAL REQUIREMENTS:

Ability to work long hours and weekends as necessary to support critical milestones

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.

Sample SpaceX interview questions

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Develop a web app that shortens URLs like TinyURL.
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Iterator over a Binary Search Tree Implement an iterator over a binary search tree. Input: root = [7,3,15,null,null,9,20], calls: next(), hasNext(), next() Output: 3, TRUE, 7 Explanation: The iterator yields the smallest value (3), confirms more nodes exist, then properly yields the next in-order value (7).
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Count Anagrammatic Substrings Count the number of anagrammatic substrings from one string present in another. Input: s = "abab", p = "ab" Output: [0, 1, 2] Explanation: The substrings "ab", "ba", and "ab" starting at indices 0, 1, and 2 respectively are all anagrams of the string "ab".
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