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PECVD Process Engineer, Solar Cells (Starlink)

SpaceX
Bastrop, USA
Junior · 1+ years experience
Onsite
Discovered 1 weeks ago
pythonsql

Full Job Posting

RESPONSIBILITIES:

  • Design, qualify, and optimize PECVD processes for SHJ intrinsic passivation layers and p-type/n-type doped layers, ensuring film thickness uniformity, passivation quality (minority carrier lifetime, implied Voc), doping efficiency, and contact resistivity at GW-scale volumes
  • Lead process development for new toolsets and materials, including gas chemistry, plasma power and frequency, pressure, temperature, and electrode gap optimization to support state of the art efficiency cells
  • Own chamber conditioning strategy, including seasoning, in-situ/remote plasma clean recipes, and clean intervals, to control particles, cross-contamination, and run-to-run drift while maximizing tool uptime
  • Partner closely with the CVD Equipment Engineering team on tool qualification, chamber matching, preventive maintenance recovery, and throughput (UPH) improvements
  • Responsible for developing, implementing, and maintaining new and/or improved manufacturing processes, equipment, technologies, and facilities
  • Analyze production processes and machinery from a first principles, physics-based approach
  • Develop experiments to diagnose and correct manufacturing problems, utilizing robust DOE and statistical methodologies. Optimize process conditions and materials to improve the optical and electrical quality of solar cells
  • Perform defect characterization and analysis to determine root cause and develop action plans to improve yields
  • Develop project plans, budgets, and cost/benefit analysis for implementation of new processes or machines
  • Own and perform machine activation and testing with a small team of engineers and technicians
  • Prepare detailed content for technical design reviews. Demonstrate extreme ownership of the production outcome of the Starlink solar factory across yield, uptime, and cost

BASIC QUALIFICATIONS:

  • Bachelor’s degree in an engineering discipline
  • 1+ years of experience in system design, analysis, and/or system implementation (internship and extracurricular experience is applicable)
  • Ability to travel frequently for work, potentially for extended periods of time during machine buyoffs and startup
  • Ability to lift 25 lbs. unassisted
  • Lifting, standing, climbing, bending, grasping, sitting, pulling, pushing, stooping, stretching, and carrying are generally required to perform the functions of this position
  • Must be willing to work extended hours and weekends as needed
  • To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.
  • SpaceX is an Equal Opportunity Employer; employment with SpaceX is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
  • Applicants wishing to view a copy of SpaceX’s Affirmative Action Plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to [email protected].

PREFERRED SKILLS AND EXPERIENCE:

  • Master’s degree or Ph.D. in chemistry, chemical engineering, materials science, physics, or related technical discipline
  • 5+ years of hands-on experience in PECVD process engineering, preferably in SHJ/HJT or TOPCon solar, semiconductor, or display manufacturing
  • Proven track record of scaling PECVD processes to high-volume production (>1GW/year equivalent)
  • Strong understanding of vacuum systems, plasma physics, gas-phase and surface chemistry, and thin-film growth of amorphous and nanocrystalline silicon
  • Deep understanding of SHJ surface passivation and carrier-selective contacts, including epitaxial growth suppression, hydrogen content and bonding, and band alignment at the a-Si:H/c-Si interface
  • Hands-on experience with thin-film and PV characterization techniques (e.g., spectroscopic ellipsometry, FTIR, Raman crystallinity, dark/photo conductivity, Sinton lifetime, PL/EL)
  • Experience safely handling pyrophoric, toxic, and flammable process gases (e.g., silane, phosphine, diborane)
  • Experience with SPC, DoE, and lean manufacturing principles
  • Ability to work in a cleanroom environment
  • Hands-on experience working with complex fluid or mechanical based production systems in a professional setting
  • Experience transitioning products from design to manufacturing and scaling to high volume as part of a cross-functional team
  • Self-motivated with strong organizational, written, and oral communication skills
  • Experience with solar cell manufacturing equipment, such as wet chemical processing equipment, PE-CVD equipment, PVD machines, metallization and final test equipment, and wafer inspection equipment. Experience in hot-wire CVD, evaporation tools, and ALD tools are a plus.
  • Experience or expertise with perovskite solar cells or perovskite tandem solar cells
  • Experience with micro-structure analysis tools (SEM, TEM, EDX, SIMS, etc.) and optical/electrical characterization tools (UV-VIS, I-V, Resistance, etc.)
  • Familiarity with large-area, high-throughput PECVD platforms (in-line and cluster/batch) and automation/integration for inline production
  • Proficiency in data analysis/scripting (Python, R, SQL) and plasma or device simulation tools (e.g., COMSOL, Quokka, AFORS-HET)
  • Experience in cost-of-ownership modeling, capex justification, and fab ramp-ups to multi-GW scales
  • Passion for sustainable energy and space technology; prior work in photovoltaics at GW-scale a plus

ADDITIONAL REQUIREMENTS:

  • ITAR REQUIREMENTS:

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