Senior Manufacturing Engineer (Thermal Protection Systems)

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-site in 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

ITAR Requirements

Varda, like all employers, must ensure that its employees working in the United States are lawfully authorized to work in the U.S. Additionally, our employees are exposed to and have access to certain export-controlled items. Because our employees are provided access to export-controlled items, our policy is to only hire "U.S. persons" who are permitted to have access to our technology without an export license.

"US person" means: U.S. citizen, U.S. lawful permanent resident, or protected individual as defined by 8 U.S.C. 1324b(a)(3) (i.e., individual admitted to the U.S. as a refugee or granted asylum).