Manufacturing Engineer- Thermal Protection System (TPS)

About This Role

As a 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:

Eng II: $119,543-$152,749

Senior: $140,333-$179,314

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