Sr. PVD Process Engineer, Solar Cells (Starlink)

Spacex

Bastrop, TX

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JOB DETAILS

SKILLS

Affirmative Action, Alternative Energy, Analysis Skills, Automation, Broadband, Budget Management, Capital Expenditure (CAPEX), Chemical Engineering, Chemistry, Cleanroom, Commissioning, Communication Skills, Cost Benefit Analysis, Cross-Functional, Data Analysis, Electricity, Environmental Sciences, High Reliability, Identify Issues, Interviewing Skills, Lean Manufacturing, Lift/Move 25 Pounds, Manufacturing, Manufacturing Equipment, Manufacturing/Industrial Processes, Material Science, Optical Transceivers, Organizational Skills, Peripheral Vascular Disease, Physics, Plant Layout and Design, Plasma, Presentation/Verbal Skills, Process Analysis, Process Development, Process Engineering, Process Improvement, Product Design, Production Machining, Production Systems, Production Volume, Productivity Management, Project Development, Project Planning, Purchasing/Procurement, Python Programming/Scripting Language, R Programming Language, Radio Frequency, Recipe Development, Root Cause Analysis, SQL (Structured Query Language), Scripting (Scripting Languages), Search Engine Marketing (SEM), Semiconductors, Simulation, Solar Engineering, Startup, Technical Writing, Technical/Engineering Design, Test Equipment, Testing, Thin Film, Total Cost of Ownership, UV/VIS (Ultraviolet-Visible Spectroscopy), United States Department of Energy (DOE), Willing to Travel, Writing Skills, X-Ray Diffraction

LOCATION

Bastrop, TX

POSTED

Today

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. PVD PROCESS 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.

As a Sr. PVD Process Engineer, you will spearhead state of the art production processes for an internal solar cell production line, providing high efficiency and high-quality solar cells for both our latest generation Starlink satellites and for Starship missions to the Moon and Mars. You will work through the life cycle of setting up a greenfield solar cell production plant, including equipment procurement, plant design/layout, equipment commissioning and ramp-up, recipe and process development, and working to develop a world-class production team and environment.

As a Sr. PVD Process Engineer, you will own the development, optimization, and scaling of Physical Vapor Deposition (PVD) processes critical for depositing transparent conductive oxide (TCO) layers, such as ITO, and other thin films essential to high-efficiency SHJ cell performance. You will develop and iterate on the manufacturing processes and recipes to achieve a state-of-the-art silicon cell efficiency, low defect rate and cost, and high reliability cell for space-based applications. 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:

Design, qualify, and optimize PVD sputtering processes (e.g., DC/RF magnetron sputtering) for SHJ front and back contacts, ensuring uniformity, adhesion, resistivity, and optical transmission at GW-scale volumes
Lead process development for new toolsets and materials, including target management, deposition rate optimization, and defect reduction to support state-of-the-art efficiency cells
Responsible for developing, implementing, and maintaining 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
Perform defect characterization and analysis to determine root cause and develop action plans to improve yields
Develop project plans, budgets, and cost/benefit analysis for implementation of new processes or machines
Own and perform machine activation and testing with a small team of engineers and technicians
Prepare detailed content for technical design reviews, and demonstrate extreme ownership of the production outcome of the Starlink solar factory across yield, uptime, and cost

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
7+ years of hands-on experience in PVD process engineering, preferably in thin-film solar (SHJ, PERC, or CIGS), semiconductor, or display manufacturing
Proven track record of scaling PVD processes to high-volume production (>1GW/year equivalent)
Strong understanding of vacuum systems, plasma physics, sputtering dynamics, and thin-film characterization techniques (e.g., XRD, SEM, Hall effect)
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
Self-motivated with strong organizational, written, and oral communication skills
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 or expertise with perovskite solar cells or perovskite tandem solar cells
Experience with micro-structure analysis tools (SEM, TEM, EDX, SIMS, etc.) and optical/electrical characterization tools (UV-VIS, I-V, Resistance, etc.)
Expertise in SHJ-specific PVD processes, including low-temperature ITO deposition for bifacial cells
Familiarity with advanced PVD tools and automation/integration for inline production
Proficiency in data analysis/scripting (Python, R, SQL) and simulation tools (e.g., SIMTRA for sputtering).
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

ITAR REQUIREMENTS:

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

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