B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering, or equivalent experience (3-6+ years)
3+ years of manufacturing experience with thermal protection systems or advanced material bonding in aerospace or defense
Hands-on experience with ablative or reusable TPS materials like PICA, AVCOAT, or ceramic tiles
Experience with adhesive bonding processes and surface preparation methods
Ability to read and interpret engineering drawings and familiarity with GD&T
Experience writing and maintaining manufacturing process documentation
Physically able to lift 25 lbs. and work directly with hardware
Responsibilities
Own manufacturing processes for TPS production, including tile preparation and bonding
Develop and maintain work instructions and process specifications for TPS operations
Implement surface preparation and adhesive application procedures
Collaborate with design engineers for DFM feedback on tile geometry and bond joint design
Define inspection methods for TPS bonds and integrate quality gates into workflows
Lead root cause analysis for TPS non-conformances
Develop environmental conditioning requirements for TPS materials storage
Assess and procure TPS-specific tooling and handling equipment
Benefits
Eligible for stock options and/or long-term cash awards
On-site role in El Segundo, CA
Opportunity to work at the forefront of aerospace technology
High visibility in a critical manufacturing domain
Potential for career advancement in a specialized field
Full Job Description
About This Role
As the Senior Manufacturing Engineer - Thermal Protection System (TPS) at Varda, you will own the manufacturing processes for the ablative and insulative materials that protect our reentry capsules during the most demanding phase of the mission- reentry. TPS manufacturing is one of the most technically specialized disciplines in aerospace, requiring deep expertise in ablative material processing, bonding, tiling, and surface preparation. You will develop and maintain the processes that ensure every capsule's heatshield is built to survive reentry conditions, working at the frontier of materials science and production engineering. This is a rare opportunity to own a critical, high-visibility manufacturing domain at a company that is already demonstrating reentry capability on orbit. This role is open at the L2 and Senior level, with levels determined based on candidate experience.
Responsibilities
Own manufacturing processes for thermal protection system production: ablative tile/panel preparation, bonding, densification, and closeout operations
Develop and maintain detailed work instructions, process travelers, and process specifications for all TPS fabrication and installation operations
Implement surface preparation, adhesive application, and cure cycle procedures that meet TPS bond strength and thermal performance requirements
Collaborate with TPS design engineers to provide DFM feedback on tile geometry, bond joint design, and tooling access for installation
Define inspection and verification methods for TPS bonds, surface finish, and dimensional conformance; integrate quality gates into production workflows
Lead root cause analysis and corrective actions for TPS non-conformances, including bond voids, tile cracking, and surface contamination findings
Develop and control environmental conditioning requirements (temperature, humidity) for TPS materials storage and processing areas
Assess and procure TPS-specific tooling: bonding fixtures, tile templates, surface preparation tooling, and handling equipment
Basic Qualifications
B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering, or a related discipline, with consideration given to equivalent professional experience (typically 3-6+ years)
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 while working directly with hardware
Preferred Skills and Experience
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
Pay Range
Salary Range: $140,333 - $202,703/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
