About This RoleAs the
Senior Manufacturing Engineer- Structures at Varda, you will own the manufacturing processes for primary and secondary structural assemblies that form the backbone of our reentry capsules and spacecraft. From composite layup and cure operations to machined metallic substructures and bonded panel assemblies, you will bridge the gap between structural design intent and production reality. You will work shoulder-to-shoulder with structural design engineers and a skilled technician team to drive process discipline, eliminate rework, and steadily increase vehicle build cadence. This is a hands-on role for someone who understands how parts are actually made, not just how they are designed, and who is energized by the challenge of scaling a complex aerospace manufacturing operation.
Responsibilities- Own manufacturing processes for composite structures (wet layup, prepreg, autoclave/oven cure), machined metallic components, and bonded assemblies
- Develop and maintain detailed work instructions, process specifications, and manufacturing travelers for all structural build operations
- Provide DFM feedback to structural design engineers on composite part design, tooling accessibility, bond joint design, and fastener patterns
- Implement and enforce cleanliness, FOD prevention, and contamination control procedures for composite and bonded structure operations
- Lead non-conformance investigations and root cause corrective actions for structural build defects and materials issues, including dimensional discrepancies and tolerance stackups, coating failures or damage to structure or protective coatings
- Define and procure tooling - drill jigs, assembly fixtures - required to support production scaling
- Refine floor layouts and product flow for structural subassembly work cells to reduce travel time and improve throughput
- Coordinate with supply chain on incoming material inspection requirements for composite materials, adhesives, and structural raw stock
Basic Qualifications- B.S. in Mechanical or Materials Engineering, or a related discipline, with consideration given to equivalent professional experience (typically 3-6+ years)
- 3+ years of manufacturing experience with structural assembly or manufacturing - Riveted or welded structures, machined metals, or composites and bonded structures
- Strong understanding of structural static loads analysis, mechanical properties of materials and processes used to assemble riveted and bolted structures.
- Hands-on experience assembling and fabricating structural assemblies, such as welding, adhesive bonding, or riveting.
- Ability to read and interpret engineering drawings, GD&T callouts, and structural assembly models
- Experience writing and maintaining manufacturing process documentation and work instructions
- Strong problem-solving skills; able to diagnose structural build defects and drive corrective action through to closure
- Must be physically able to regularly lift 25 lbs., bend, stoop, and stand for extended periods while working directly with hardware
Preferred Skills and Experience- M.S. degree in Mechanical engineering specialized in Materials Science, Structural Analysis, or related discipline, with consideration given to equivalent professional experience
- Experience manufacturing primary flight structures for launch vehicles, satellites, or reentry systems
- Familiarity and strong understanding of dynamic and vibrational loads analysis
- Background in transitioning structural assemblies from R&D/prototype to rate production, including tooling qualification
- Knowledge of and familiarity with the manufacture of aerospace structural materials like aluminum alloys, titanium, and steel in a manufacturing context
- Experience with 3D CAD tools (CATIA, SolidWorks, NX) for tooling design and assembly model review
- Familiarity with first article inspection (FAI) processes and FAIR documentation requirements
- Prior experience at a new-space or defense prime where structural production cadence was actively being increased
Pay Range- Salary Range: Senior: $140,333-$179,314/per year
- This role is on-sitein El Segundo, CA
- Leveling and base salary is determined by job-related skills, education level, experience level, and job performance
- You will be eligible for incentives in the form of stock options and/or long-term cash awards
BenefitsConsider your benefits covered for launch. At Varda, we invest in benefits and perks that support your health, financial well-being, and life beyond work. Benefits vary by position, with packages designed specifically for our regular full-time employees and interns.
Regular Full-Time Positions:Health & Wellness
- Flexible PTO policy + 12 paid holidays
- 100% company-paid Medical, Dental, and Vision insurance plans for employees and dependents with FSA and employer-matched HSA options
- Voluntary accident, hospital, critical illness, and pet insurance
- $120/month wellness reimbursement for gym and fitness expenses
- 12 weeks of parental leave (with supplemental disability leave for CA mothers)
- Family building, pregnancy, parenting and menopause benefits via Maven Clinic
- Sponsored One Medical memberships for employees and their dependents
Financial & Retirement
- Substantial incentive equity in a fully funded space start-up
- 401(k) retirement plan with 6% employer match (immediately vested)
- $20/pay period cell phone reimbursement
- Relocation support for new hires, if needed
Workplace Experience & Perks
- Fully stocked kitchen with lunch provided daily and dinner provided twice weekly
- Company and team-bonding events, happy hours and mission-success celebrations
- Complimentary EV charging
Intern Positions:Health & Wellness
- Paid observed holidays
- 100% company-paid Medical, Dental, and Vision insurance plans for employees and dependents with FSA and employer-matched HSA options
- $120/month wellness reimbursement for gym and fitness expenses
- Sponsored One Medical memberships for employees and their dependents
Financial
- $20/pay period cell phone reimbursement
- Up to $4,000 gross up in relocation support, if eligible
- Up to $850 commute credit through Lyft or car rental reimbursement, if eligible
Workplace Experience & Perks
- Fully stocked kitchen with lunch provided daily and dinner provided twice weekly
- Company and team-bonding events, happy hours and mission-success celebrations
- Complimentary EV charging
