Thermal Protection System (TPS) Manufacturing Engineer

Varda Space Industries•El Segundo, CA

2d•$119,543 - $179,314•Onsite

About The Position

As a Thermal Protection System (TPS) Manufacturing Engineer 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.

Requirements

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

Nice To Haves

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

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

Benefits

Flexible PTO policy + 12 paid holidays
100% company-paid Medical, Dental, and Vision insurance plans for employees and dependents with FSA and employer-matched HSA options
Voluntary accident, hospital, critical illness, and pet insurance
$120/month wellness reimbursement for gym and fitness expenses
12 weeks of parental leave (with supplemental disability leave for CA mothers)
Family building, pregnancy, parenting and menopause benefits via Maven Clinic
Sponsored One Medical memberships for employees and their dependents
Substantial incentive equity in a fully funded space start-up
401(k) retirement plan with 6% employer match (immediately vested)
$20/pay period cell phone reimbursement
Relocation support for new hires, if needed
Fully stocked kitchen with lunch provided daily and dinner provided twice weekly
Company and team-bonding events, happy hours and mission-success celebrations
Complimentary EV charging