Supplier Development Engineer, Assembly Processes (Starlink)

SUPPLIER DEVELOPMENT ENGINEER, ASSEMBLY PROCESSES (STARLINK)

Starlink User Terminal business is experiencing exponential growth across consumer, retail, enterprise, and mobility applications. This rapid expansion requires a highly resilient and scalable supply chain with world-class precision assembly processes at contract manufacturers. The role entails early engagement in supplier selection, equipment selection, and process engineering to set programs up for success in high-volume manufacturing by ensuring material and process corners are fully completed. The role also includes ownership to deliver on time, monitor field performance, react to issues, and feed lessons learned back to engineering teams for iterative improvement.

We are seeking a technically strong Supplier Development Engineer to drive equipment bring-up and process development for critical joining, dispensing, and inspection technologies. This role focuses on developing robust, high-volume manufacturing processes for hardware to be manufactured at contract manufacturers, with emphasis on plastic and metal joining methods, precision material dispensing, and automated quality inspection. The Supplier Development Engineer, Assembly Processes will be responsible for end-to-end process development and qualification of joining, dispensing, and inspection systems. This position demands deep manufacturing process expertise and extreme ownership from early equipment selection through process characterization, line qualification, and field performance feedback.

RESPONSIBILITIES:

• Own end-to-end process development, equipment bring-up, and qualification for precision assembly technologies at contract manufacturers, spanning strategic supplier selection, new product introduction (NPI), and high-volume production
• Engage early with suppliers on equipment selection, tooling design, and process engineering to properly set up high-volume manufacturing programs by ensuring material and process corners are fully characterized and completed
• Lead development of ultrasonic welding processes, including amplitude, force, energy, weld time, and trigger optimization, as well as horn design, joint geometry, and weld strength validation for both metal and thermoplastic components
• Develop hot plate welding and vibration welding processes for plastic housings and enclosures, focusing on temperature uniformity, platen design, melt displacement control, weld pressure profiles, and long-term joint durability
• Optimize heat staking and hot riveting processes for plastic boss forming, including temperature control, pressure profiling, staking tool design, and dimensional stability validation
• Develop and qualify precision dispense processes for thermal interface materials (TIM), adhesives, and sealants, including rheological characterization, volumetric vs. time-pressure dispensing, needle selection, vision-guided positioning, and repeatable bead or dot formation
• Establish and optimize automated optical inspection (AOI) systems, including multi-angle lighting techniques, high-resolution imaging, algorithm development, false call reduction, and integration with deep learning-based defect detection
• Design and execute comprehensive design of experiments (DOE) and corner case studies (material and process windows) to define robust parameter ranges and ensure process capability across environmental and material variations
• Lead line qualification activities at contract manufacturers, including equipment installation qualification (IQ), operational qualification (OQ), performance qualification (PQ), gauge repeatability and reproducibility (GR&R), and production part approval process (PPAP)
• Develop detailed process control plans, failure mode and effects analysis (FMEA), statistical process control (SPC) limits, and reaction plans to sustain high process capability in mass production
• Perform reactive quality engineering support, including rapid containment, root cause analysis using eight disciplines (8D) and five-whys (5-Why) methodologies, and corrective actions for quality escapes, field returns, and production issues
• Own on-time delivery of process qualification and production ramp activities while continuously monitoring field performance, reacting quickly to issues, and feeding lessons learned from field data back to design and process engineering teams for iterative improvement

BASIC QUALIFICATIONS:

• Bachelor’s degree in mechanical engineering, manufacturing engineering, materials science, or other engineering discipline
• 1+ years of experience in precision joining, dispensing, and automated inspection process development for consumer electronics or complex hardware

PREFERRED SKILLS AND EXPERIENCES:

• Strong technical background in ultrasonic welding, hot plate welding, vibration welding, precision dispensing, and automated optical inspection
• Hands-on experience bringing up and qualifying ultrasonic welding, hot plate welding, vibration welding, and heat staking processes in high-volume production environments
• Deep expertise in thermal interface material (TIM) and sealant dispensing, including viscosity control, dispense valve technology, and closed-loop feedback systems
• Strong experience developing automated optical inspection (AOI) systems, including illumination optimization, image processing, and defect classification algorithms
• Expertise in statistical methods including design of experiments (DOE), statistical process control (SPC), process capability analysis (Cp/Cpk), and measurement system analysis (MSA)
• Experience leading full line qualification (IQ/OQ/PQ) and production part approval process (PPAP) at contract manufacturers
• Knowledge of relevant standards including IPC-A-610, IPC-J-STD-001, ISO 9001, and AS9100
• Strong problem-solving skills using structured root cause analysis methods and statistical tools such as Minitab and design of experiments (DOE)
• Excellent written and verbal communication skills with the ability to distill complex technical topics into clear one-pagers, process characterization reports, and executive presentations
• Demonstrated ability to influence cross-functional teams and contract manufacturers in a fast-paced, high-growth environment

ADDITIONAL REQUIREMENTS:

• Ability to travel up to 30% of the time, both domestically and internationally
• Position may require extended working hours and occasional weekends to support equipment bring-up and production ramps
• This position is based in Bastrop, TX and requires being onsite