Process Engineer, Spacecraft Corrosion & Cleanliness (Starship)

PROCESS ENGINEER, SPACECRAFT CORROSION & CLEANLINESS (STARSHIP)

As a Process Engineer, Spacecraft Corrosion & Cleanliness on the Super Heavy and Starship programs, you will take extreme ownership for activating, qualifying, optimizing, and ensuring the consistency of operations for painting Super Heavy Boosters to protect against corrosion, while driving cleanliness standards across Starship vehicles to eliminate FOD and achieve proper chemical fluid cleaning. You will develop and productionize processes, equipment, and protocols critical to the reliability and performance of the world's most powerful and reusable rocket systems, enabling humanity's multiplanetary future.

RESPONSIBILITIES:

• Demonstrate extreme ownership in the activation, qualification, optimization, and consistent operation of painting processes for Super Heavy Boosters, including substrate preparation (mechanical abrasion, chemical etchants), advanced paint system mixing/application (epoxies, urethanes, solvent-based paints), sealants/adhesives, and curing/overcoat schedules
• Develop, implement, and maintain cleanliness protocols for Starship components and assemblies, ensuring zero FOD through inspections, specialized cleaning techniques, chemical fluid processes, and controlled environments (e.g., cleanrooms)
• Analyze process data, lab results, production metrics, and feedback to diagnose issues, perform root cause analysis, and optimize for corrosion protection, cleanliness levels, yield, uptime, and cost
• Design, commission, and troubleshoot fluid systems, chemical processing, and painting tools (e.g., spray systems, precision measurement devices like elcometers/ohmmeters), including maintenance and balance-of-plant calculations
• Collaborate with manufacturing, engineering, EHS, and operations teams to define requirements, develop work instructions, technical drawings, and best practices; conduct audits, training, and preventative measures for FOD and contamination control
• Lead experiments using DOE/statistical methods to improve paint adhesion/corrosion resistance and cleaning efficacy; develop project plans, budgets, and cost/benefit analyses for process upgrades or new equipment
• Monitor area status, risks, and compliance with SpaceX specs, regulatory standards, and safety protocols (e.g., lockout/tagout, chemical handling); champion continuous improvement and lean manufacturing initiatives
• Prepare technical content for design reviews and support interdisciplinary projects from concept through ramp-up in a fast-paced production environment

BASIC QUALIFICATIONS:

• Bachelor's degree in chemical, mechanical, aerospace, materials, or other engineering discipline
• 1+ years of hands experience in process engineering, fluid/chemical systems, manufacturing, or coatings/painting operations (internship or project experience applicable)

PREFERRED SKILLS AND EXPERIENCE:

• 3+ years of experience in aerospace manufacturing, advanced coatings/paint systems, cleanliness/FOD control, or wet chemical processes
• Experience with corrosion protection, paint application (e.g., epoxies, urethanes), substrate preparation, or precision measurement in high-reliability environments
• Strong knowledge of fluid dynamics, thermodynamics, surface chemistry, and process optimization; familiarity with P&IDs, PFDs, CAD (NX/SolidWorks), and statistical tools
• Hands-on work with cleanroom operations, chemical cleaning, FOD prevention, or cryogenic/chemical fluid systems
• Proven ability to lead cross-functional teams, execute in high-pressure settings, and transition processes from R&D to high-volume production
• Excellent communication skills, self-motivation, and passion for advancing human spaceflight

ADDITIONAL REQUIREMENTS:

• Must be willing to work extended hours and/or weekends as needed