Sr. Solar Cell Reliability Engineer (Starlink)

SR. SOLAR CELL RELIABILITY ENGINEER (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 we vertically integrate critical hardware, we are building and scaling heterojunction (HJT) solar cell production to power spacecraft and constellation assets with higher efficiency, lower mass, and proven reliability in the space environment.

We are looking for a Sr. Solar Cell Reliability Engineer who will own the reliability lab and the end-to-end reliability story for our solar cells in space-from wafer and cell process through module integration, environmental qualification, on-orbit performance, and continuous improvement back into manufacturing. Your work will ensure our solar cells deliver unmatched power density and durability for Starship, Starlink, AI Sat, and deep-space missions. 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 and operate the solar cell reliability lab: equipment strategy, capability roadmap, calibration, maintenance, safety, throughput, and data integrity for HJT cell and coupon reliability testing
• Define, execute, and continuously improve the space reliability test matrix for HJT solar cells (e.g., thermal cycling, thermal vacuum, humidity/damp heat as applicable, UV/photo-stability, reverse bias / hotspot, mechanical shock/vibration at cell/coupon level, radiation exposure coordination, and accelerated life tests)
• Build and own the reliability narrative for flight and program reviews: failure modes, physics of failure, acceleration models, life predictions, margins, and acceptance/qualification logic that ties lab data to on-orbit performance
• Partner with HJT process and equipment engineering (texturing, PECVD/a-Si stacks, TCO, metallization, module integration) to link process parameters, metrology, and in-line defects to reliability outcomes; drive corrective actions and design-for-reliability changes
• Establish reliability gates for process changes, tool qualifications, material substitutions, and supplier changes; own risk assessment (FMEA/PFMEA interfaces), sampling plans, and release criteria
• Develop and maintain test methods, SOPs, fixturing, and automation for high-throughput, statistically defensible reliability characterization; ensure methods are transferable and auditable
• Lead root cause analysis on reliability failures (electrical, optical, interfacial, mechanical, environmental) using SEM/FIB, EDS, FTIR, PL/EL, IV, quantum efficiency, adhesion, and other failure-analysis techniques; close the loop with manufacturing and design
• Define and track reliability KPIs (e.g., degradation rates, wear-out distributions, infant mortality, lot-to-lot variation, correlation of accelerated tests to flight-like stress) and report status to leadership with clear recommendations
• Interface with power systems, structures, thermal, radiation effects, quality, and flight reliability teams so cell-level reliability is coherent with array/module and spacecraft environments
• Support flight anomaly investigation and on-orbit performance trending; update models and test strategies as flight data matures.
• Mentor technicians and junior engineers; set lab culture for rigor, speed, and honest interpretation of data
• Author and present technical content for design reviews, production readiness reviews, and customer/internal reliability packages as required

BASIC QUALIFICATIONS:

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

PREFERRED SKILLS AND EXPERIENCE:

• Master's degree or Ph.D. in chemistry, chemical engineering, materials science, environmental, or related technical discipline (especially in PV, thin-film devices, reliability physics, or space power systems)
• 7+ years of hands-on experience in solar cell, PV module, semiconductor device, or aerospace hardware reliability (internship/co-op experience may count toward this if highly relevant and hands-on)
• Experience designing, running, or analyzing accelerated environmental or reliability tests and interpreting degradation / failure data
• Proficiency with data analysis (e.g., Python, MATLAB, JMP, R, or equivalent) and comfort with statistics (distributions, confidence bounds, DOE basics)
• Ability to work full-time on-site in a production and lab environment
• Strong understanding of vacuum systems, plasma physics, sputtering dynamics, and thin-film characterization techniques (e.g., XRD, SEM, Hall effect)
• Hands-on experience with PV metrology tools (eg. Sinton lifetime, EL/PL) and reliability testing
• Experience with SPC, DoE, and lean manufacturing principles
• 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

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
• Willing to work extended hours and weekends as needed