Staff Materials and Process Engineer

Viasat; Arizona; On-site; USD 176,000 - 264,000; Full time

Job summary

Viasat is seeking a Staff Materials & Process Engineer to lead research, selection, and qualification of advanced materials for next-generation space platforms. You will drive process development and collaborate across engineering, manufacturing, supply chain, quality, and program management.

The ideal candidate combines deep expertise in spacecraft materials with independent problem solving and leadership across teams, mentoring rising engineers and contributing to the full lifecycle from

Qualifications

• Bachelor's degree in Materials Science, Chemical Engineering, Metallurgy, Mechanical or Aerospace Engineering or related field.
• 10+ years of materials and process engineering experience in space hardware development.
• Experience leading materials and process development for spacecraft, satellites, or aerospace systems.
• Knowledge of high-performance composites, core materials, surface treatments, coatings, and bonding processes.
• Hands-on experience with composite manufacturing (hand lay-up, vacuum bagging, cure optimization).
• Familiarity with material characterization and analytical testing (FTIR, DSC, DMA).
• Experience defining, qualifying, and troubleshooting manufacturing shop floor processes and C/CA actions.
• Strong problem-solving, communication, and cross-functional collaboration skills.
• U.S. Citizenship required.

Responsibilities

• Lead materials and process engineering efforts for satellite structures, mechanisms, payloads, and deployable assemblies.
• Develop specs, processing guidelines, and assembly procedures for composite, metallic, and non-metallic materials.
• Define problems, run trade studies, and design engineering solutions balancing performance, schedule, cost, and risk.
• Own material properties characterization, design allowables, test programs, and process specs from concept to on-orbit support.
• Perform and direct material failure analysis, life predictions, and DoE to improve manufacturing efficiency and quality.
• Review and approve drawings, specs, and manufacturing instructions; ensure subcontractor procedures meet requirements.
• Lead qualifications, hardware integration, shop floor support, and corrective actions.
• Drive design reviews (PDR/CDR/TRR/FRR) and provide technical recommendations to leadership.
• Collaborate with mechanical, systems, thermal, manufacturing, quality, and supply chain teams.
• Evaluate new technologies, materials, and processes to improve capability and scale.
• Provide mentorship and guidance to junior engineers and designers.
• Serve as SME in spacecraft materials and processing.

Skills

Materials engineering

Process engineering

Spacecraft materials

Composite materials

Adhesive bonding

Surface treatments

Education

Bachelor's degree in Materials Science or related field

Tools

FTIR

DSC

DMA

Job description

About us

One team. Global challenges. Infinite opportunities. At Viasat, we’re on a mission to deliver connections with the capacity to change the world. For more than 35 years, Viasat has helped shape how consumers, businesses, governments and militaries around the globe communicate. We’re looking for people who think big, act fearlessly, and create an inclusive environment that drives positive impact to join our team.

What you'll do

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.

The day-to-day

In this role, you will 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.

You will:

• 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.

What you'll need

• 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.

What will help you on the job

• 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.

Salary range

$141,500.00 - $224,000.00 / annually.For specific work locations within San Jose, the San Francisco Bay area and New York City metropolitan area, the base pay range for this role is $176,000.00- $264,000.00/ annually

At Viasat, we consider many factors when it comes to compensation, including the scope of the position as well as your background and experience. Base pay may vary depending on job-related knowledge, skills, and experience. Additional cash or stock incentives may be provided as part of the compensation package, in addition to a range of medical, financial, and/or other benefits, dependent on the position offered. Learn more about Viasat’s comprehensive benefit offerings that are focused on your holistic health and wellness at https://careers.viasat.com/benefits.

EEO Statement

Viasat is proud to be an equal opportunity employer, seeking to create a welcoming and diverse environment. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity or expression, sexual orientation, national origin, ancestry, physical or mental disability, medical condition, marital status, genetics, age, or veteran status or any other applicable legally protected status or characteristic. If you would like to request an accommodation on the basis of disability for completing this on‑line application, please click here.