Sr. Process Engineer, Mold Flow

SR. PROCESS ENGINEER, MOLD FLOW

SpaceX is leveraging its experience in building rockets and spacecraft to deploy Starlink, the world’s most advanced broadband internet system. Starlink is the world’s largest satellite constellation and is providing fast, reliable internet to 4M+ users worldwide. We design, build, test, and operate all parts of the system – thousands of satellites, consumer products that allow users to connect within minutes of unboxing, and the software that brings it all together. We’ve only begun to scratch the surface of Starlink’s potential global impact. As we continue to upgrade and expand the constellation, we’re looking for best-in-class engineers to join the team.

As a Sr. Process Engineer on the Materials Tool & Die team, you will play a key role in optimizing the manufacturing processes for our Starlink consumer hardware. From the initial design phase through tooling qualification, you will work to enhance mold performance, streamline production processes, and minimize material waste. Your contributions will directly support the growth and success of the Starlink program as we expand our global broadband service.

RESPONSIBILITIES

• Inform engineering teams by offering your expertise in plastic molding, identifying ways to enhance manufacturability and mold performance.
• Collaborate with engineers on Design for Manufacturability (DFM), addressing potential manufacturability challenges before the tooling phase.
• Work with engineers to fine-tune tooling strategies, including runner, gate, and cooling designs, to ensure molds are both efficient and accurate.
• Focus on optimizing molding processes, reducing cycle times, improving efficiency, and minimizing defects.
• Make use of advanced molding simulation tools to boost production operations, reduce material waste, and ensure every part meets the highest standards of quality.
• Analyze data from simulations, and improve and refine molding processes, contributing to a more streamlined and efficient production cycle.

BASIC REQUIREMENTS

• Bachelor’s degree in mechanical, manufacturing, materials engineering, or other engineering discipline
• 5+ years of experience running Moldflow software simulations
• 3+ years of experience working with injection molding machines, operations, setup, and processing of molds and auxiliary equipment.

PREFERRED REQUIREMENTS

• Excellent knowledge of engineering thermoplastic resins, processing, tooling, and troubleshooting.
• Familiarity with analysis tools and methods to solve technical problems (e.g. 3D modeling, mold filling analysis, finite element analysis).
• Understanding of DFM, with the ability to provide early design feedback.
• Ability to work with cross-functional teams and suppliers.
• Ability to analyze and interpret Flow, Pack, Cool, and Warp simulations to diagnose issues and optimize design, material use, and cycle times.
• Experience in molding simulation, with expertise in tools such as Moldflow, Moldex3D, or similar software.
• Understanding of injection molding processes, tooling design, and mold performance for high-volume production of consumer hardware.

COMPENSATION AND BENEFITS:    

Pay range:    
Process Engineer/Senior: $125,000.00 - $175,000.00/per year    
     
Your actual level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills, education, and experience.

Base salary is just one part of your total rewards package at SpaceX. You may also be eligible for long-term incentives, in the form of company stock, stock options, or long-term cash awards, as well as potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan. You will also receive access to comprehensive medical, vision, and dental coverage, access to a 401(k) retirement plan, short and long-term disability insurance, life insurance, paid parental leave, and various other discounts and perks. You may also accrue 3 weeks of paid vacation and will be eligible for 10 or more paid holidays per year. Exempt employees are eligible for 5 days of sick leave per year.