Process Controls Engineer, Solar Cell Factory (Starlink) Verified today

Role

The Solar Cell team manufactures high-efficiency solar cells to power Starlink constellations, launch vehicles, and beyond. As a Process Controls Engineer, you will design, build, and optimize controls and automation systems for the delivery of critical gases and chemicals in solar cell fabrication. You will work on vacuum deposition and etching processes, managing hazardous materials in a high-volume manufacturing environment while ensuring reliable control code and safe system design.

Responsibilities

• Design, implement, and maintain automation systems including PLC programming and SCADA development for gas farm operations (vaporizers, storage, and transfer systems) and wastewater treatment processes (solids separation, clarification, and chemical dosing)
• Develop and program PLC control logic, PID loops, and interlocks for centralized control of distributed subsystems, optimizing for real-time monitoring of pressure, temperature, flow, pH, and effluent quality
• Select, calibrate, and integrate field instrumentation (transmitters, sensors, analyzers) in hazardous environments, ensuring compatibility with SIL, ATEX, and EPA/NPDES regulations
• Lead commissioning, FAT/SAT testing, and troubleshooting of control systems, performing root-cause analysis to minimize downtime and support 24/7 operations with rapid alarm response
• Design electrical systems compliant with NEC, NFPA, and UL508A regulations

Basic Qualifications

• Bachelor's degree in engineering, physics, or chemical discipline
• 1+ years of experience with fluids/systems manufacturing, controls and automation, and/or programming (internship and extracurricular experience applicable)

Preferred Skills and Experience

• Comfortable with quick, iterative design and manufacturing
• Proven ability to solve complex problems with simple solutions
• Excellent written and verbal communication with ability to collaborate cross-functionally
• Engineering creative approaches while adhering to ANSI/RIA15.06/OSHA safety requirements
• Hazardous process expertise in aerospace, oil and gas, or chemical industry with high-pressure or hazardous fluid/gas systems

Electrical and Industrial Controls

• Electrical sizing of motors, valves, pneumatics, cables, circuit protection, VFDs, motor starters, and motion systems
• Design of fail-safe electrical circuits using safety logic controllers and safety-rated relays
• Hands-on troubleshooting of industrial electrical systems using multimeters, oscilloscopes, EMI probes
• Proficiency creating electrical schematics and single line diagrams (EPLAN preferred)
• Field bus networks, serial communication, Profinet and Ethernet communications
• Hands-on design and commissioning of electrical panels and electro-mechanical systems with safety considerations
• Knowledge of NEC, NFPA, UL508A codes and control system safety standards compliance

Industrial Software

• PLC programming, preferably Siemens TIA Portal structured text and ladder logic
• HMI, SCADA, IoT (MQTT, OPC-UA), Ignition systems with focus on user-friendly navigation and machine health monitoring
• Field bus networking protocols, preferably EtherCAT, Profinet, Profisafe, Ethernet/IP
• Robotics programming, preferably ABB
• Industrial software application to mechanical assemblies, electrical systems, sensors, pneumatics/hydraulics, including safe checkout of interdisciplinary systems prior to production

Additional Requirements

• Ability to work long hours and weekends as necessary to support critical milestones

ITAR Requirements

To conform to U.S. Government export regulations, applicant must be a U.S. citizen or national, U.S. lawful permanent resident (green card holder), Refugee under 8 U.S.C. Section 1157, or Asylee under 8 U.S.C. Section 1158, or be eligible to obtain the required authorizations from the U.S. Department of State.