Principal Manufacturing Engineer (Thermal Protection Systems)

Varda Space•El Segundo, CA

2d•Onsite

About The Position

Varda is seeking a Principal Manufacturing Engineer specializing in Thermal Protection Systems (TPS) to own manufacturing processes for the ablative and insulative materials used to protect its reentry capsules. The role focuses on developing and maintaining processes for ablative material processing, bonding, tiling, surface preparation, and heatshield installation to ensure capsules can withstand reentry conditions. The engineer will work with materials science and production engineering at Varda’s El Segundo production facility.

Requirements

B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering, or a related discipline; equivalent professional experience may be considered.
At least 6 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 such as 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.
Ability to regularly lift 25 lbs., bend, stoop, and stand for extended periods while working directly with hardware.
Must be a U.S. person as defined in the posting and authorized to work in the United States, due to access to export-controlled items.

Nice To Haves

Direct experience manufacturing TPS for reentry vehicles, hypersonic glide vehicles, or planetary entry capsules.
Familiarity with TPS inspection methods, including visual inspection, tap testing, and NDE methods applicable to bonded ceramic or ablative tiles.
Knowledge of TPS material properties such as ablation rates, density gradients, and outgassing behavior, and their manufacturing implications.
Experience with environmental controls and material-handling requirements for moisture-sensitive TPS materials.
Experience transitioning TPS manufacturing from bespoke development builds to repeatable, documented production processes.
Experience with robotic or semi-automated TPS tile application processes.
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.

Responsibilities

Own TPS manufacturing processes, including ablative tile and panel preparation, bonding, densification, and closeout operations.
Develop and maintain work instructions, process travelers, and process specifications for TPS fabrication and installation.
Implement surface preparation, adhesive application, and cure-cycle procedures that meet bond strength and thermal performance requirements.
Collaborate with TPS design engineers and provide design-for-manufacturing feedback on tile geometry, bond-joint design, and tooling access.
Define inspection and verification methods for TPS bonds, surface finish, and dimensional conformance, and 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.
Develop and control environmental conditioning requirements for TPS material storage and processing areas.
Assess and procure TPS-specific tooling, including bonding fixtures, tile templates, surface-preparation tooling, and handling equipment.