Materials Engineer, Additive Manufacturing

Our Propulsion Materials team is responsible for developing and qualifying laser powder bed fusion (LPBF) processes for nickel-based superalloys used in next-generation rocket engines. In this role you will own process development, parameter optimization, and material characterization for high-performance components on Raptor engines.

You will work daily with design and manufacturing teams to push the limits of what is possible with LPBF nickel superalloys and other materials. If you have significant hands-on experience developing and qualifying LPBF processes for nickel-based superalloys and want to apply that expertise to the most demanding propulsion applications, this is the role for you.

- Provide materials and process support for propulsion system designs and manufacturing

- Increase reliability of internal designs and manufacturing processes through material and process development

- Develop physical, mechanical, and thermal properties for materials

- Improve our additive processes and materials through characterization and development, with a primary focus on laser powder bed fusion of nickel-based superalloys

- Work directly with our additive engineering and manufacturing teams daily

- Perform root cause investigations using fractography, metallography, and testing

- Provide technical reviews and advice for design efforts specifically related to drawings, specifications, and material requirements

- Collaborate with other engineers, subject matter experts, and technicians to solve complex material and processing challenges on our current and next-generation vehicles

- Bachelor's degree in materials engineering or other engineering discipline with emphasis on materials

- 1+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)

- Master's degree or PhD in materials engineering or related field

- 3+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)

- Direct experience with LPBF parameter development, build optimization, and post-processing (HIP, heat treatment, surface finishing)

- Experience with metallurgical characterization and mechanical testing of additively manufactured nickel alloys

- Experience with one or more of the following manufacturing methods: additive (laser powder bed fusion), direct energy deposition (DED), casting, forging, brazing, heat treating

- Understanding of mechanical testing methods for metals including fracture and fatigue

- Familiarity with standard testing methods for materials and development of design allowables

- Experience with failure analysis and fractography including characterization techniques such as Scanning Electron Microscopy (SEM) and metallographic analysis

- Knowledge of aerospace metals including nickel-based alloys, stainless steels, aluminum alloys, and titanium alloys

- Understanding of non-destructive test methods for fracture control

- Proven track record developing design allowables or material specifications for LPBF nickel alloys

- Experience with fracture mechanics, fatigue, and creep testing of additively manufactured superalloys

- Hands-on experience with process monitoring, in-situ sensors, or advanced process control for LPBF

- Extended hours and weekend work may be required to support critical project and mission milestones

Pay Range: Level 1: $100,000.00 - $117,500.00 Level 2: $115,000.00 - $140,000.00

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 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. Employees accrue paid sick leave pursuant to Company policy which satisfies or exceeds the accrual, carryover, and use requirements of the law.