Metallization Process Engineer - Solar Cells (Starlink)

METALLIZATION ENGINEER - SOLAR CELLS (STARLINK) 

Starlink believes in providing fast, reliable internet to those who 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. And while our hardware and network are incredibly advanced, we keep the end-user experience impressively simple - our customers have internet within 10 minutes of unboxing. 

As a metallization process engineer on Starlink, you will spearhead state-of-the-art production processes for an internal solar cell production line, providing high-efficiency and high-quality solar cells for both our latest generation Starlink satellites and for Starship missions to the Moon and Mars. You will work through the life cycle of setting up a greenfield solar cell production plant, including equipment procurement, plant design/layout, equipment commissioning and ramp-up, recipe and process development, and working to develop a world-class production team and environment. Example processes include chemical etching, PE-CVD, PVD, metallization, and cell test equipment, wafer inspection tools, evaporation and ALD equipment, ultrapure and wastewater treatment equipment, and gas and chemical distribution systems, among others.

You will develop and iterate on the manufacturing processes and recipes to achieve a state-of-the-art silicon cell efficiency, low defect rate and cost, and high reliability cell for space-based applications. 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: 

• Responsible for developing, implementing, and maintaining new and/or improved manufacturing processes, equipment, technologies, and facilities


• Analyze production processes and machinery from a first principles, physics-based approach


• Develop experiments to diagnose and correct manufacturing problems, utilizing robust DOE and statistical methodologies


• Optimize process conditions and materials to improve the optical and electrical quality of solar cells


• Perform defect characterization and analysis to determine root cause and develop action plans to improve yields


• Develop project plans, budgets, and cost/benefit analysis for implementation of new processes or machines


• Own and perform machine activation and testing with a small team of engineers and technicians


• Prepare detailed content for technical design reviews and demonstrate extreme ownership of the production outcome of the Starlink solar factory across yield, uptime, and cost

BASIC QUALIFICATIONS: 

• Bachelor’s degree in an engineering discipline


• 1+ years of experience in chemical engineering design, analysis, and/or system implementation (internship and extracurricular experience is applicable)

PREFERRED SKILLS AND EXPERIENCE: 

• Master’s degree or PhD in chemistry, chemical engineering, materials science, environmental engineering, or related technical discipline


• Hands-on experience working with complex fluid or mechanical based production systems in a professional setting


• Experience transitioning products from design to manufacturing and scaling to high volume as part of a cross-functional team


• 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


• Experience or expertise with perovskite solar cells or perovskite tandem solar cells


• Experience with micro-structure analysis tools (SEM, TEM, EDX, SIMS, etc.) and optical/electrical characterization tools (UV-VIS, I-V, Resistance, etc.)

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


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