Sr. Product Design Engineer, Consumer Hardware (Starlink) - job 1 of 2

As a Sr. Product Design Engineer at SpaceX, you will own the end-to-end development of Starlink consumer hardware, from conceptual design through to high-volume production. You’ll collaborate on design criteria, iterate on product testing to ensure field reliability, and develop production lines, including automation and control system design. Your role will be pivotal in fulfilling the mission of connecting the world through our advanced broadband system.

To qualify for the Sr. Product Design Engineer position at SpaceX, you should have a Bachelor’s degree in an engineering discipline and a minimum of 5 years of experience in mechanical or electromechanical design. Proficiency in CAD and FEA software is essential, along with hands-on experience in complex mechanical systems. A Master’s degree and significant experience in design for manufacturability are preferred.

The Sr. Product Design Engineer at SpaceX significantly contributes to Starlink's success by designing consumer hardware that meets the diverse needs of users around the world. Their expertise ensures that products are not only technologically advanced but also easy to use, enhancing the overall user experience. Additionally, their role in developing efficient production lines ensures that high-quality products are delivered quickly and reliably to customers.

Preferred skills for the Sr. Product Design Engineer role at SpaceX include experience with 3D CAD software (NX preferred), knowledge of GD&T principles, and a thorough understanding of structural analysis and failure modes in mechanical systems. Familiarity with manufacturing processes and the ability to lead complex design projects from concept through production are also highly valued.

SpaceX offers tremendous opportunities for growth to a Sr. Product Design Engineer, including involvement in groundbreaking projects that push the limits of technology. Engineers can expand their skill set through hands-on experience in a fast-paced environment, collaborate with top talents in the industry, and contribute meaningfully to initiatives that have a significant global impact, opening doors for career advancement and innovation.

When designing consumer hardware, I start by understanding user needs and testing market requirements. I then develop conceptual designs and iterate through prototypes, focusing on functionality, ease of use, and manufacturability, while ensuring the product meets all design criteria before moving to production.

In a previous role, I worked on a complex mechanical component for a consumer product. The challenge lay in ensuring durability while maintaining a lightweight structure. By applying advanced simulation techniques and iterative design improvements, I was able to refine the component, leading to successful testing and a successful market launch.

I approach production line design by first collaborating with cross-functional teams to identify requirements. I conduct feasibility studies and use CAD and automation tools to create efficient layouts. Throughout implementation, I focus on optimizing processes while monitoring performance metrics to ensure quality and efficiency.

I have substantial experience in automation programming, having designed control systems for robotic assembly. This involved programming PLCs and coordinating with hardware engineers to integrate sensor feedback systems, ultimately improving production speed and accuracy.

Collaboration with cross-functional teams has been a major part of my work. I routinely coordinate efforts of engineering, manufacturing, and quality assurance to ensure that designs meet production capabilities and market needs, fostering open communication and teamwork to tackle challenges.

I prioritize tasks by assessing their impact on overall project goals and deadlines. I develop a structured timeline and set clear milestones, ensuring that critical tasks receive attention first without compromising the quality of deliverables. Regular check-ins with the team help manage workload effectively.

I stay updated through continuous learning, attending industry conferences, and participating in relevant webinars. I also subscribe to engineering journals and follow industry leaders on professional networks to gather insights and trends that can be applied to my work.

My approach to testing involves developing a thorough test plan that outlines performance metrics and failure criteria. I analyze test data to identify design flaws, iterating on the design as needed, and validating improvements through retesting to ensure the product meets all reliability and performance standards.

I have utilized a variety of technologies, including CAD software for 3D modeling and simulations, FEA tools for structural analysis, and rapid prototyping technologies to create physical models quickly for testing and validation. Each tool is chosen based on project needs.

During a product launch, we faced unexpected performance issues. I spearheaded a cross-functional task force to analyze and identify the cause. By troubleshooting and implementing a series of design modifications based on team feedback, we improved performance and ensured a successful launch.