Materials Engineer, Additive Manufacturing

Materials Engineer, Additive Manufacturing

Location:

Hawthorne, CA

SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

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 another 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 allowable
• Experience with failure analysis and fractography including techniques such as SEM and metallographic analysis
• Knowledge of aerospace metals including nickel-based alloys, stainless steels, aluminum alloys, and titanium alloys
• Hands‑on experience in a manufacturing environment
• 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
• Up to 10% domestic travel is expected

Pay Range:

• Level 1: $ – $
• Level 2: $ – $

Base salary is determined on a case-by-case basis and may vary based on job‑related knowledge and skills, education, and experience.

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