Sr. Device Physics Engineer, Solar Cells (Starlink)

SR. DEVICE PHYSICS ENGINEER, SOLAR CELLS (STARLINK)

Starlink believes in providing fast, reliable internet to those that need it most. We design, build, and launch the world's largest and most advanced satellite constellation that is capable of delivering high-speed internet to even the most remote locations.

We are seeking an exceptional Sr. Device Physics Engineer to lead end-to-end cell efficiency ownership in our high-volume silicon heterojunction (SHJ) solar cell fab. Acting as the central process integration expert, you will collaborate with specialized process and equipment engineers to maximize cell performance to achieve state of the art efficiency, define wafer specifications, design space-optimized cell architectures, and establish comprehensive metrology and reliability frameworks. Your work will span from ingot growth all the way through cell production (wafer prep, deposition, passivation, metallization) and module fabrication. Your work will ensure our solar cells deliver unmatched power density and durability for Starship, Starlink, AI Satellites, and deep-space missions.

You will spearhead state of the art production processes, and work through the entire life cycle of setting up a greenfield solar cell production plant, including equipment/lab procurement, plant design/layout, equipment commissioning and ramp-up, recipe and process development, and working to develop a world-class production team and environment. Your work will form the backbone of the Starlink network (photons of sunlight in is directly proportional to photons of data out to customers!) and help provide internet to tens of millions of customers all around the world.

RESPONSIBILITIES:

• Own end-to-end cell efficiency roadmap: integrate processes across ingot growth, wafer prep, deposition (PECVD, PVD), passivation, metallization, and testing to drive significant efficiency gains
• Define and qualify incoming wafer specifications (e.g., resistivity, lifetime, thickness uniformity) for SHJ compatibility, partnering with suppliers and internal supply for tens of GW-scale volumes
• Design and iterate SHJ cell architectures optimized for space: Radiation tolerance (proton/electron fluence), thermal vacuum cycling, UV exposure, and high specific power (>250 W/kg)
• Develop fab-wide metrology strategy: Select, commission, and calibrate inline/offline tools (e.g., lifetime testers, IQE/EL mappers, TRPL, LBIC, SEM, Ellipsometry, Raman, etc.) for real-time process control and yield correlation
• Lead reliability engineering: Establish accelerated life testing labs (HALST, damp heat, mechanical stress, radiation, TVAC, UV, etc.), define qualification protocols per ECSS/AEC-Q standards, and predict 25+ year mission lifetimes
• Build and maintain physics-based models (e.g., PC1D, Quokka, Sentaurus) for loss analysis (recombination, shading, passivation) and guide DoE with process teams
• Analyze production data to identify efficiency limiters, spearhead cross-functional improvements, and support fab ramps
• Mentor team on PV physics fundamentals and represent solar cell performance in design reviews for spacecraft power systems
• Develop, implement, and maintain new and/or improved manufacturing processes, equipment, technologies, and facilities
• Analyze production processes and machinery from a first principles, physics-based approach
• Develop experiments to diagnose and correct manufacturing problems, utilizing robust DOE and statistical methodologies
• Optimize process conditions and materials to improve the optical and electrical quality of solar cells
• Develop project plans, budgets, and cost/benefit analysis for implementation of new processes or machines
• Prepare detailed content for technical design reviews
• Demonstrate extreme ownership of the production outcome of the Starlink solar factory across yield, uptime, and cost
• Scale lab/pilot level processes to production environments, working closely with the process engineering team

BASIC QUALIFICATIONS:

• Bachelor's degree in an engineering discipline
• 5+ years of experience in chemical engineering design, analysis, and/or system implementation

PREFERRED SKILLS AND EXPERIENCE:

• Master's degree or Ph.D. in chemistry, chemical engineering, materials science, environmental, or other STEM discipline
• Strong understanding of vacuum systems, plasma physics, sputtering dynamics, and thin-film characterization techniques (e.g., XRD, SEM, Hall effect)
• 7+ years of experience in solar cell physics, device modeling, or process integration in PV (SHJ, PERC, TOPCon, HJT preferred)
• Deep understanding of SHJ efficiency drivers: Surface passivation, carrier selectivity, TCO optics, and space degradation mechanisms
• Hands-on experience with PV metrology tools (eg. Sinton lifetime, EL/PL) and reliability testing
• Proficiency in PV simulation software and statistical data analysis. Proficiency in data analysis/scripting (Python, R, SQL) and simulation tools (e.g., SIMTRA for sputtering)
• Expertise in advanced SHJ topics: Poly-Si contacts, bifacial optimization, or perovskite tandems for >30% targets
• Strong publication record in PV conferences/journals and experience leading multidisciplinary teams
• Experience with SPC, DoE, and lean manufacturing principles
• Ability to work in a cleanroom environment
• Hands-on experience working with complex fluid or mechanical based production systems in a professional setting
• Experience transitioning products from design to manufacturing and scaling to high volume as part of a cross-functional team
• Experience with solar cell manufacturing equipment, such as wet chemical processing equipment, PE-CVD equipment, PVD machines, metallization and final test equipment, and wafer inspection equipment (experience in evaporation tools and ALD tools are a plus)
• Experience with micro-structure analysis tools (SEM, TEM, EDX, SIMS, etc.) and optical/electrical characterization tools (UV-VIS, I-V, Resistance, etc.)
• Experience in cost-of-ownership modeling, CapEx justification, and fab ramp-ups to multi-GW scales
• Passion for sustainable energy and space technology; prior work in photovoltaics at GW-scale a plus

ADDITIONAL REQUIREMENTS:

• Ability to travel frequently for work, potentially for extended periods of time during machine buyoffs and startup
• Ability to lift 25 lbs. unassisted
• Lifting, standing, climbing, bending, grasping, sitting, pulling, pushing, stooping, stretching, and carrying are generally required to perform the functions of this position
• Must be willing to work extended hours and weekends as needed