Materials R&D Specialist

MATERIALS R&D SPECIALIST

Starlink is building the world's largest satellite constellation to deliver fast, reliable internet to people who need it most—and powering that constellation starts on the factory floor. We are insourcing solar cell manufacturing end-to-end, from crystal growth and ingot production through wafering and cell fabrication, to drive performance, cost, and scale at every step. High-efficiency, high-reliability cells made in-house are the backbone of the Starlink network: more photons in means more data out to customers around the world.

As a Materials R&D Specialist, you will partner with engineering to stand up and operate processes and to drive process development for insourced solar cell manufacturing, from silicon ingot growth through cell metrology. You will independently execute processing, characterization, and equipment work, recommend experimental plans, and help transfer stable methods to production. The materials you process will feed the solar cells that power next-generation Starlink satellites and Starship missions to the Moon and Mars.

RESPONSIBILITIES:

• Partner with engineering to bring processes and equipment online and to drive process development, equipment qualification, and test method development from silicon ingot growth through wafering and cell metrology
• Independently perform routine and non-routine processing and experimental methods for crystal growth, wafer fabrication, and/or cell metrology; identify next steps and recommend complete process plans to engineers
• Identify and put in place new processing methods, standards, and equipment, including the required documentation; make practical improvements to lab and line operations
• Commission, install, calibrate, maintain, and troubleshoot process and metrology equipment (e.g., crystal pullers, wafer process tools, and characterization instruments); diagnose issues that affect process or test results and work with engineering and OEMs to correct them
• Perform hands-on materials work such as preparing seeds and hot-zone components for crystal growth, wafer processing (cropping, slicing, cleaning, surface conditioning), and preparing samples for characterization and production trials
• Execute DOEs and process trials covering recipe development, thermal management, impurity and defect control, contamination control, and supplier material evaluation
• Perform silicon ingot, wafer, and cell characterization (e.g., lifetime, resistivity, FTIR, microscopy, and related methods) and keep lab equipment maintained and calibrated
• Document procedures and data so work is repeatable and traceable; write SOPs, training documents, and work instructions; train production technicians and other team members as methods move to manufacturing
• Work with engineering on design, testing, and process development; present results clearly and provide recommendations based on the data
• Handle chemicals safely and follow all EHS protocols; keep the lab and cleanroom organized to meet 5S standards

BASIC QUALIFICATIONS:

• Bachelor's degree in materials science, chemistry, chemical engineering, or another STEM discipline; or a minimum of 4 years of hands-on laboratory experience (internship, co-op, and relevant academic laboratory coursework are applicable)

PREFERRED SKILLS AND EXPERIENCE:

• Hands-on experience in semiconductor or photovoltaic manufacturing, silicon crystal growth, wafer manufacturing, materials characterization, or a similar laboratory or manufacturing environment
• Experience using and maintaining materials-characterization or process equipment (e.g., microscopy, spectroscopy, electrical or optical metrology, wet benches, or related equipment)
• Demonstrate ability to run processing and experimental methods independently, analyze data, and determine the cause of irregular results
• Experience writing SOPs, training documents, or work instructions, and training others to follow them
• Experience handling flammable, toxic, corrosive, or hazardous chemicals safely (academic laboratory experience is applicable)
• Experience installing, calibrating, and maintaining process or characterization equipment, including diagnosing issues that affect results
• Experience recommending and executing processing or experimental plans and transferring stable methods to production
• Proven ability to understand and accurately follow complex laboratory and manufacturing procedures and adhere to safety requirements; strong attention to detail
• Comfortable with data collection, documentation, and basic statistical analysis in a clear, organized manner
• Strong interpersonal, verbal, and written communication skills; ability to work with engineers, technicians, and cross-functional teams and summarize technical results
• Ability to set priorities and determine the next step needed to move a project forward
• Ability to shift roles and responsibilities while working independently in a fast-paced, challenging environment with limited oversight

ADDITIONAL REQUIREMENTS:

• Must be open to work all shifts, overtime and/or weekends as needed
• Must be comfortable working in a production and laboratory environment using hazardous chemicals such as acids, alkalis, and solvents
• Must be able to wear appropriate PPE for lab and electro-chemical manufacturing environments
• Must be able to walk and stand for long periods of time
• Must be able to lift 25 lbs. unassisted
• Must be comfortable with climbing up and down ladders, grasping, standing, lifting, bending, pulling, pushing, stooping, stretching, carrying, crawling, and maneuvering in tight spaces