Senior Manufacturing Engineer (Thermal Protection Systems)

The role

You will own manufacturing processes for ablative and insulative materials that protect reentry capsules. You will develop work instructions, implement bonding procedures, and collaborate with design engineers on DFM feedback.

What you will do

• Own manufacturing processes for thermal protection system production
• Develop and maintain detailed work instructions, process travelers, and process specifications
• Implement surface preparation, adhesive application, and cure cycle procedures
• Collaborate with TPS design engineers to provide DFM feedback
• Define inspection and verification methods for TPS bonds, surface finish, and dimensional conformance
• Lead root cause analysis and corrective actions for TPS non-conformances
• Develop and control environmental conditioning requirements for TPS materials
• Assess and procure TPS-specific tooling

Required qualifications

• B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering, or a related discipline
• 3+ years of manufacturing experience with thermal protection systems, composite materials, or advanced material bonding in aerospace or defense
• Hands-on experience with ablative or reusable TPS materials: PICA, AVCOAT, SLA-561, cork composites, ceramic tiles, or equivalent
• Experience with adhesive bonding processes, surface preparation methods, and cure cycle control for structural or TPS bonds
• Ability to read and interpret engineering drawings and TPS assembly models
• Familiarity with GD&T as applied to complex surface geometries
• Experience writing and maintaining manufacturing process documentation for specialized materials operations
• Must be physically able to regularly lift 25 lbs., bend, stoop, and stand for extended periods

Nice to have

• Direct experience manufacturing TPS for reentry vehicles, hypersonic glide vehicles, or planetary entry capsules
• Familiarity with TPS inspection methods: visual inspection, tap testing, NDE methods applicable to bonded ceramic or ablative tiles
• Knowledge of TPS material properties — ablation rates, density gradients, outgassing behavior — and their manufacturing implications
• Experience with environmental controls and material handling requirements for moisture-sensitive TPS materials
• Background in transitioning TPS manufacturing from bespoke development builds to repeatable, documented production processes
• Experience with robotic or semi-automated TPS tile application processes is a strong plus
• Familiarity with reentry thermal analysis and how TPS design margins translate into manufacturing quality requirements
• Prior work at a company with demonstrated reentry or hypersonic vehicle flight heritage

Benefits

• Stock options
• Long-term cash awards

Before you apply

• Must be a U.S. person (U.S. citizen, U.S. lawful permanent resident, or protected individual)
• Must be lawfully authorized to work in the U.S.

About the company

Varda is accelerating the development of commercial space infrastructure, from in-orbit pharmaceutical processing to reliable and economical reentry capsules. The company is headquartered in El Segundo, California.