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Sr. Materials Engineer, Thin Films

SpaceX· Materials Engineering - Starlink Materials
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Bastrop, TXfull-timePosted 3w ago

About the role

Senior engineer focusing on thin-film PECVD processes for solar-cell manufacturing within Starlink, driving materials understanding, specifications, and process improvements to boost efficiency, yield, reliability, and cost.

Responsibilities

  • Partner with solar cell process engineering on PECVD thin films (e.g., passivation, anti-reflection, and related dielectric or semiconductor layers), developing materials requirements, film-property targets, and the physical understanding of how deposited films perform in the cell
  • Build deep technical understanding of plasma-deposited film materials: composition, hydrogen content, density, stress, optical constants, passivation quality, interfaces, and reliability; translate that understanding into clear recommendations that improve cell performance and manufacturability
  • Operate as the technical expert for thin-film materials: independently apply advanced materials concepts to highly complex issues, develop new characterization or evaluation methods where they do not already exist, and make high-impact materials decisions with limited tactical guidance
  • Set your own priorities from program needs; execute multiple complex, multi-month materials projects in parallel (new film stacks, materials qualification, yield or reliability recovery, supplier materials) and come to leadership with solved problems and already-implemented solutions
  • Partner with process engineering on DOEs and process trials: define materials-relevant responses, interpret how plasma, chemistry, and hardware changes affect film properties and cell results, and recommend durable improvements
  • Define film material requirements, specifications, and acceptance criteria; qualify precursors, consumables, and film stacks so materials used in production are understood, controlled, and scalable
  • Lead structured root cause analysis for materials-limited performance, yield, and reliability issues (film defects, interface failure, contamination, stoichiometry, stress, delamination); correlate process history with metrology and drive corrective actions to first principles
  • Influence cross-functional decisions with process, equipment, quality, production, and characterization teams; challenge assumptions that do not serve cell performance or manufacturability; create materials methods, specifications, and tools that raise the bar for others
  • Identify and drive path-finding for advanced thin-film materials, stacks, or precursor chemistries that deliver measurable gains in efficiency, reliability, or cost
  • Coordinate with suppliers on precursors, consumables, and film materials to reduce supply-chain risk and ensure long-term scalability
  • Mentor engineers, new hires, and interns on thin-film materials, PECVD-relevant materials science, and first-principles problem solving; generate and share high-quality engineering content, specifications, and best practices
  • Champion a culture of safety and quality in all vacuum, plasma, pyrophoric/toxic gas, chemical handling, lab, and production support activities

Qualifications

  • Bachelor's degree in materials science, chemical engineering, electrical engineering, physics, or a STEM discipline
  • 5+ years of professional experience with thin films, PECVD or other vacuum-deposited coatings, or electronic materials in a manufacturing or R&D environment

Skills

Required:Thin-film materials sciencePECVD process knowledgeMetrology and characterizationRoot cause analysisMaterials specification & qualificationCommunication & collaborationSafety & quality culture
Nice to have:Data analysisLeadership & mentoring

Benefits

  • SpaceX is an Equal Opportunity Employer; information on benefits is described in company policies (not specified in this text)
Last updated Sep 30, 2026. Interested? Apply on the company site.

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