Starship Engineer, FOD Control

STARSHIP ENGINEER, FOD CONTROL

As a Starship Engineer specializing in FOD Control, you will own Foreign Object Debris (FOD) prevention and elimination across Starship Production while developing engineering and manufacturing processes that maximize quality at high rate. You will employ root cause investigations and data review to deploy robust fabrication methods, work instructions, tooling design, inspection and cleaning measures. Engineering design, process, facility and supply chain controls will all be areas of ownership.

RESPONSIBILITIES:

• Own FOD control strategy and execution for Starship Production; ensure facilities and processes comply with AS9146 (Foreign Object Debris Prevention Program) and related aerospace/defense standards.
• Partner with design engineering to apply Design for Manufacturability (DFM) and design-for-cleanliness principles—sealing machined areas, eliminating hidden cavities where debris can lodge, and enabling clean assembly line layouts—while influencing flight design and vehicle architecture.
• Develop and enforce manufacturing, integration, assembly, welding, NDE, cleanliness, and checkout processes across work centers, including Clean-As-You-Go methodologies, tool accountability tracking, and hardware kitting protocols.
• Design and implement precision tooling and poka-yoke systems for work access, build fixturing, lifting & rigging, fluids, and mechanical/avionics/propulsion testing to eliminate assembly error, prevent FOD introduction, improve quality, and minimize cycle time.
• Develop, qualify, and automate manufacturing processes and in-situ inspection techniques to enable high-rate, repeatable production with higher yield and lower takt time.
• Evaluate and integrate automated FOD detection systems, millimeter-wave radar, and specialized mechanical sweeping equipment into production and integration environments.
• Define inspection requirements, author planning/test plans/work instructions, and create training for production and inspection—including FOD awareness—ensuring stable quality as volume scales.
• Contain non-conforming hardware with quality, production, and design; conduct build quality and FOD audits to identify high-impact issues; drive corrective action and manage fleet risk.
• Challenge and simplify requirements where design intent, cleanliness, and production rate conflict; manage transition of parts and assemblies from development to high-rate production with FOD controls built in.

BASIC QUALIFICATIONS:

• Bachelor's degree in mechanical engineering, aerospace engineering, materials engineering, manufacturing engineering, chemical engineering, electrical engineering, engineering physics, or other engineering discipline.
• 1+ years in manufacturing, quality, process design, and/or design engineering (student project team or internship experience qualifies).

PREFERRED SKILLS AND EXPERIENCE:

• Master's degree in an engineering discipline.
• Experience developing or leading FOD prevention, cleanliness, contamination control, or AS9146 (or equivalent) programs.
• Hands-on experience with high-rate or mixed value stream manufacturing, focused on yield, rate, and process control.
• Experience building, assembling, or integrating aerospace hardware (structures, avionics, propulsion, fluids, valves, actuators, thermal protection, or similar).
• Mechanical tooling or component design with strong DFM; proficiency in assembly methods, testing, FMEA, and troubleshooting.
• Proficiency with 3D CAD (NX, SolidWorks, or CATIA).
• Knowledge of welding (MIG, TIG, laser, stud, spot, or robot) and NDT (visual, penetrant, x-ray, EMAT, or other); experience improving weld processes and inspection, including automation.
• Knowledge of metallic manufacturing processes (machining, forming, casting, additive, fastening, drilling, bonding).
• Experience evaluating or deploying automated inspection, sensing, detection, or shop-floor cleanup technology.
• Proficiency with SQL, Power BI, or similar tools to prioritize work and measure performance.
• Collegiate or hobby design project experience (Formula SAE, rocketry, etc.); thrives hands-on on the shop floor.
• Strong interpersonal skills and ability to collaborate across diverse engineering disciplines.

ADDITIONAL REQUIREMENTS:

• Ability to work extended hours, weekends, and offsite as needed; schedule varies with site operational needs.
• Flexibility to travel to remote build sites, up to 10%.
• Flight hardware is built in tight quarters; physical dexterity required. Duties may include standing, kneeling, crouching, twisting, working in cramped openings, and climbing (including ladders/stairs up to 6 hours/day).
• Work may involve extreme outdoor environments (heat, cold, rain), temperatures over 80°F for 6+ hours/day, and exposure to fumes, odors, and noise.