Sr. PVD Process Engineer, Solar Cells (Starlink)
Core
Spearhead state-of-the-art production processes for an internal solar cell production line, providing high efficiency and high-quality solar cells for Starlink satellites and Starship missions.
Role type
Sr. PVD Process Engineer (Solar Cells)
Builds
High-efficiency SHJ solar cells for space-based applications (Starlink, Starship)
Domain
Aerospace / Photovoltaics / Thin-film manufacturing
Deliverable
production ML models | product features | dashboards & analysis | research | client delivery | infrastructure | physical/clinical work -> physical/clinical work (manufacturing infrastructure)
Required skills
PVD process development and optimization, vacuum systems, plasma physics, sputtering dynamics, thin-film characterization, DOE and statistical methodologies, defect analysis, project planning and budgeting, cleanroom operations, scaling processes to high-volume production
Preferred skills
Master's or Ph.D. in chemistry/chemical engineering/materials science, experience scaling PVD processes to >1GW/year, expertise in SHJ-specific PVD processes (low-temperature ITO), perovskite solar cell experience, micro-structure analysis tools (SEM, TEM, EDX, SIMS), optical/electrical characterization tools (UV-VIS, I-V), Python/R/SQL scripting, SIMTRA simulation, cost-of-ownership modeling
Technologies
DC/RF magnetron sputtering, ITO, SHJ, XRD, SEM, Hall effect, SPC, SIMTRA, Python, R, SQL
Responsibilities
Design, qualify, and optimize PVD sputtering processes for SHJ front and back contacts; Lead process development for new toolsets and materials; Develop experiments to diagnose and correct manufacturing problems; Perform defect characterization and analysis to determine root cause; Develop project plans, budgets, and cost/benefit analysis for implementation of new processes; Own and perform machine activation and testing with a small team of engineers and technicians
Seniority
Senior, hands-on IC