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TEST ENGINEER, BATTERY DEVELOPMENT

The Development Test team is responsible for testing that supports every major program at the company: Starship, Dragon, Falcon, and Starlink. We aim to excel at operating in situations where there is uncertainty and embrace the unexpected outcomes that result from testing. Our engineers specialize in the design and execution of unique tests for engines, components, and spacecraft on an accelerated schedule. This role offers a constant variety of diverse engineering challenges in a fast-paced, hands-on team environment.

The Battery Test group is a fast-paced R&D focused team that aims to increase reliability by testing next-generation batteries used in every the company program. As a battery test engineer, you will design, fabricate, and implement a comprehensive suite of battery test equipment, and lead fully assembled pack-scale development testing aimed at ensuring the reliability, safety, and performance of battery systems. This individual should be passionate about batteries with a background in mechanical engineering.

RESPONSIBILITIES:

• Create test fixturing concepts, fabrication drawings, wiring schematics, and to establish mechanical, thermal, and electrical tests necessary for rapid development of battery packs.
• Repeated ownership of test campaigns, including test plan creation, new system activation, test operations, data review, and test stand equipment design/fabrication/maintenance.
• Establish rigorous safety protocols for high voltage applications and various destructive tests of batteries.
• Provide daily direction and instruction to technicians to fabricate and integrate test articles and stand equipment.
• Develop and maintain test procedures, sequences, scripts, configuration files, and software.
• Operate and troubleshoot data acquisition and control systems, wiring, and instrumentation. DAQ systems are primarily National Instruments-based.
• Design, fabricate, operate and troubleshoot fluid and mechanical systems that include low to high-pressure gaseous working fluids and rocket propellants (including hypergols & cryogenics), test stand support structures, heat exchangers, vacuum pumps, tooling, and fluid components such as valves, reliefs, burst disks, tubing, etc.
• Automate repetitive test operations to increase efficiency and safety. Develop innovative processes to increase testing capability and rates, while maintaining high rigor of safety and attention to detail.
• Identify and characterize system pitfalls and potential hazards then work to resolve such anomalies by collaborating with design engineers on improvements for test stands and flight hardware.

BASIC QUALIFICATIONS:

• Bachelor’s degree in mechanical engineering, aerospace engineering, electrical engineering or related engineering field
• 1+ years of hands-on testing experience (experience from internships, clubs or other hands-on extra-curricular activities qualifies)

PREFERRED SKILLS AND EXPERIENCE:

• 2+ years of hands-on experience with mechanical systems, structural systems, fluid systems, flight hardware or test operations
• Experience with design and handling of hazardous systems (high-pressure, high-voltage, cryogenic, flammable, hypergolic)
• Experience with lithium-ion battery handling, safety and usage
• Familiarity with battery cell first principles
• Familiarity with instrumentation and control components (pressure transducers, thermocouples, resistance temperature detectors (RTDs), strain gauges, accelerometers, flow meters, load cells, relays, solenoid, pneumatic valves)
• Experience using 3D modeling software (Siemens NX, Inventor, CATIA, etc.)
• Experience with at least one coding language (Python, Matlab, C, C++, Java, Visual Basic)
• Experience reviewing data from anomalies and identifying root cause
• Experience writing and maintaining test procedures and hardware work instructions
• Creative ability to imagine and design from scratch, while retaining low cost, reliability, efficiency, and maintainability
• Ability to read, understand and apply technical manuals, data reports, mechanical schematics, electrical schematics and design specifications
• Ability to communicate well in a collaborative environment - should enjoy working on a team and be able to be work efficiently with others, including in stressful situations such as rapid pace operations and times of limited resources

ADDITIONAL REQUIREMENTS:

• Flight hardware is typically built in tight quarters and physical dexterity is required
• Physical effort including sitting or standing for extended periods of time, lifting and carrying weight such as materials or equipment up to 25 lbs. unassisted
• Work performed in an environment with exposure to fumes, odors and noise
• Occasionally exposed to work in extreme outdoor environments (heat, cold, rain)
• Must be available to work extended hours, weekends, and shifts, which varies depending on site operational needs; flexibility required