Thermal Protection System (TPS) Engineer (ES3)

Amentum•Huntsville, AL

3d•Hybrid

About The Position

The Non‑Metallic Materials and Space Environmental Effects Team is seeking a Thermal Protection System (TPS) Engineer to lead the development, processing, and verification of aerospace thermal protection materials and application methods. This role provides engineering direction for TPS technicians and is responsible for planning, documenting, and overseeing the execution of TPS activities including spray‑foam application, aerospace coatings, pour foams, adhesives, surface preparation, and machining‐related operations. The TPS Engineer will ensure that all work meets engineering, quality, and safety requirements while supporting flight and development hardware.

Requirements

Bachelor’s degree in engineering (Mechanical, Materials, Chemical, Aerospace, or related field) from an ABET accredited university and experience working with materials, coatings, or manufacturing processes.
Demonstrated ability to develop, follow, and enforce detailed procedures and engineering instructions.
Experience with polymer‑based materials, coatings, adhesives, or TPS‑related systems.
Familiarity with lab or shop environments involving hands‑on hardware processing.
Strong documentation, communication, and technical writing skills.
Ability to work independently and provide direction to technicians executing engineering tasks.
Must be a US Citizen and have a STAR ID

Nice To Haves

Experience with aerospace TPS materials, including spray foams, ablative coatings, adhesives, and specialized insulative systems.
Prior leadership or oversight of technicians or shop-floor operations.
Experience with paint/coating operations, surface prep standards, or application parameter engineering.
Background in machining, fixture design, or hardware preparation for materials processing.
Familiarity with NASA or aerospace material specifications and configuration control processes.
Experience with automated spray, mixing, or robotic application systems.

Responsibilities

Provide technical leadership and daily guidance to TPS technicians performing foam spraying, coating application, adhesive bonding, surface preparation, masking, and machining operations.
Develop and maintain engineering process documentation, including work instructions, material process specifications, and verification plans.
Plan and oversee TPS processing activities, ensuring proper material selection, environmental controls, equipment configuration, and quality compliance.
Conduct engineering evaluations of TPS materials, including processing trials, cure studies, and application parameter optimization.
Review technician documentation, verify process adherence, and ensure full traceability of materials and hardware.
Coordinate with engineers, project leads, and quality representatives to ensure TPS processing meets all program and mission requirements.
Support troubleshooting of spray equipment, mixing/dispensing systems, and environmental controls, providing engineering direction for corrective actions.
Perform engineering analyses related to TPS performance, process capability, or material behavior.
Lead or assist in the design of fixtures, tooling, and test setups used for TPS applications and verification.
Review hardware for process readiness, including surface condition, masking layout, dimensional checks, and part configuration.
Participate in design reviews, safety reviews, and customer technical discussions related to TPS materials and processes.
Recommend and implement process improvements, including material changes, new equipment, or updated procedures.