Staff Materials and Process Engineer

Viasat, Inc.•Karlovy Vary, Arizona

About The Position

ViaSat is seeking a highly motivated Staff Materials & Process Engineer to join our growing space infrastructure team. In this role, you will lead the research, selection, analysis, design, and qualification of advanced materials and their associated fabrication and application processes for next-generation satellite platforms. You will serve as a key technical contributor across the full product lifecycle, driving innovative solutions for challenging spaceflight applications while collaborating with multidisciplinary teams across engineering, manufacturing, supply chain, quality, and program management. The ideal candidate combines deep technical expertise in spacecraft materials and processing—including composites, metallic/non-metallic systems, adhesive bonding, and surface treatments—with the ability to independently solve complex problems, influence technical direction, and mentor developing engineers.

Requirements

Bachelor's degree in Materials Science, Chemical Engineering, Metallurgy, Mechanical Engineering, Aerospace Engineering, or related engineering discipline.
10+ years of materials and process engineering experience, including significant experience developing spaceflight hardware.
Demonstrated experience leading materials and process development for spacecraft, satellites, launch vehicles, or other aerospace systems.
Strong working knowledge of high-performance composite materials (carbon/epoxy, carbon/cyanate resin systems), core materials, surface treatments/coatings, and adhesive bonding processes.
Hands-on working experience with composite manufacturing processes, including hand lay-up, vacuum bagging, and cure cycle optimization.
Familiarity with material characterization and analytical test methods such as FTIR, DSC, DMA, and mechanical property testing.
Experience defining, qualifying, and troubleshooting manufacturing shop floor processes, as well as developing Cause and Corrective Actions (C/CA).
Ability to independently solve complex technical problems with limited direction.
Strong written and verbal communication skills, including presentation of technical data to management and customers.
Experience working within cross-functional product development teams.
U.S. Citizenship required.

Nice To Haves

Master's degree or PhD in Materials Science and Engineering or related field.
Experience with small satellite, broadband constellation, or spacecraft bus development programs.
Experience with composite structures, lightweight design, and outgassing/radiation environmental impacts on materials.
Familiarity with DFM/DFA principles, SPC methodologies, and production scaling of aerospace materials and hardware.
Experience with Teamcenter, Windchill, or other PLM systems.
Experience supporting suppliers and contract manufacturers, including reviewing subcontractor material processing procedures.
Knowledge of spaceflight material standards, workmanship requirements, and environmental qualification methodologies.
Experience performing root cause failure investigations and driving corrective actions.
Previous experience mentoring engineers and providing technical leadership across teams.

Responsibilities

Lead and contribute to projects and programs of significant scope and complexity, applying advanced engineering principles to develop reliable, manufacturable, and cost-effective spacecraft materials and processes.
Lead materials and process engineering efforts for satellite structures, mechanisms, payload systems, and deployable assemblies.
Apply principles of chemistry, physics, and material behavior to develop composite, metallic, and non-metallic material specifications, processing guidelines, and assembly procedures.
Independently define problems, evaluate trade studies, and develop engineering solutions that balance performance, schedule, cost, and risk.
Own material properties characterization, design allowable, material test programs, and engineering process specifications from concept through qualification, production, and on-orbit support.
Perform and direct material failure analysis of components and subsystems, life predictions, and Design of Experiments (DOE) to improve manufacturing efficiency and quality.
Review and approve engineering documentation including drawings, specifications, Manufacturing Work Instructions, and down-flowed process requirements.
Lead materials and process qualifications, hardware integration, shop floor support, and Cause and Corrective Action (C/CA) activities.
Drive Design Reviews (PDR, CDR, TRR, FRR) and provide material/process technical recommendations to program leadership.
Collaborate closely with mechanical, systems, thermal, manufacturing, quality, and supply chain teams to ensure successful product execution, including reviewing and approving subcontractor processing procedures.
Evaluate new technologies, materials, and manufacturing processes to improve product capability, quality, and scalability.
Provide technical mentorship and guidance to junior engineers and designers.
Serve as a recognized subject matter expert in one or more areas of spacecraft materials and process engineering.