Thermal Protection System (TPS) Manufacturing Engineer

Vardaspace; El Segundo (CA); On-site; USD 120,000 - 179,000; Full time

Benefits offered by this job

Health insurance

401(k) retirement plan with 6% match

Relocation assistance

Stock options

Job summary

Varda Space Industries in El Segundo, CA seeks a Thermal Protection System (TPS) Manufacturing Engineer to own ablative and insulative heatshield production for reentry capsules. Develop and maintain processes, travelers, and specs to ensure reliable TPS performance.

Ideal candidates have 3–6+ years in aerospace TPS manufacturing and bonding, with hands-on experience in TPS materials, surface prep, and quality verification.

Qualifications

• B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering or equivalent experience.
• 3+ years of manufacturing experience in TPS, composites, or advanced bonding.
• Hands-on with ablative or reusable TPS materials (PICA, AVCOAT, tiles, etc.).
• Experience reading engineering drawings and GD&T for complex geometries.
• Experience writing and maintaining manufacturing process docs.
• Must be able to lift 25 lbs and stand for extended periods.

Responsibilities

• Own TPS production processes: tile/panel prep, bonding, densification, closeout.
• Create and maintain work instructions, process travelers, specs.
• Implement surface prep, adhesive application, cure cycles.
• Provide DFM feedback on tile geometry and tooling access.
• Define inspection methods for TPS bonds and finishes.
• Lead root-cause and corrective actions for TPS issues.
• Set environmental controls for TPS materials storage.
• Evaluate TPS tooling and fixtures procurement.

Skills

Materials science

Aerospace manufacturing

TPS bonding

GD&T

Engineering drawings

Process documentation

Physical stamina

Education

B.S. in Materials Science or related engineering

Tools

Measurement tools

Process travelers

Job description

About Varda

Low Earth orbit is open for business. Varda is accelerating the development of commercial space infrastructure, from in-orbit pharmaceutical processing to reliable and economical reentry capsules.Varda’s W-Series vehicles are built, designed, and operated by Varda in-house, including the pharmaceutical processing payloads, the capsules, the C-PICA heat shields, and the satellite buses.

From life-saving pharmaceuticals to more powerful fiber optics, there is a world of products used on Earth today that can only be manufactured in space. Varda is accelerating innovation in the orbital economy by creating both the products and infrastructure needed so space can directly benefit life on Earth. Our mission is to expand the economic bounds of humankind.

Our team is uniquely suited to accomplishing this goal, with leadership and staff comprised of veterans from SpaceX, Blue Origin, major pharmaceutical companies and Silicon Valley. Varda was founded in January 2021 by Will Bruey and Delian Asparouhov with significant backing from world class investors including Khosla Ventures, Lux Capital, Founders Fund, Caffeinated Capital, General Catalyst, and Also Capital.

Varda is headquartered in El Segundo, California, where we have offices and a production facility where our vehicles, equipment, and materials are built, integrated, and tested. Varda also has offices in Washington, DC and Huntsville, AL.

Join Varda, and work to create a bustling in-space ecosystem.

About This Role

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.

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 ison‑sitein 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

Benefits

Consider your benefits covered for launch.At Varda, we invest in benefits andperksthat support your health, financial well-being, and life beyond work. Benefits vary by position, with packages designed specifically for our regular full‑time employees and interns.

Regular Full‑Time Positions:

Health & Wellness

• 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,andpet insurance

• $120/month wellness reimbursement for gym and fitness expenses

• 12weeks ofparental leave(with supplemental disability leavefor CAmothers)

• Family building, pregnancy,parentingand menopausebenefitsvia Maven Clinic

• SponsoredOne Medicalmemberships for employees and their dependents

Financial & Retirement

• Substantial incentive equityin a fully funded space start‑up

• 401(k) retirement plan with 6% employer match (immediatelyvested)

• $20/pay period cell phone reimbursement

• Relocation supportfor new hires, if needed

Workplace Experience & Perks

• Fully stocked kitchen with lunch provided daily and dinner provided twice weekly

• Company and team‑bonding events, happyhoursand mission‑success celebrations

• Complimentary EV charging

Benefits forInternship Positions:

Health & Wellness

• Paidobservedholidays.

• 100% company‑paid Medical, Dental, and Vision insurance plans for employees and dependents with FSA and employer‑matched HSA options.

• $120/month wellness reimbursement for gym and fitness expenses.

• Sponsored One Medical memberships for employees and their dependents.

Financial

• $20/pay period cell phone reimbursement.

• Up to $4,000gross up in relocation support, ifeligible

• Up to $850commute credit through Lyft or car rental reimbursement, if eligible.

Workplace Experience & Perks

• Fully stocked kitchen with lunch provided daily and dinner provided twice weekly

• Company and team‑bonding events, happyhoursand mission‑success celebrations

• Complimentary EV charging

ITAR Requirements

Varda, like all employers, must ensure that its employees working in the United States are lawfully authorized to work in the U.S. Additionally, our employees are exposed to and have access to certain export‑controlled items. Because our employees are provided access to export‑controlled items, our policy is to only hire “U.S. persons” who are permitted to have access to our technology without an export license.“US person” means: U.S. citizen, U.S. lawful permanent resident, or protected individual as defined by 8 U.S.C. 1324b(a)(3) (i.e., individual admitted to the U.S. as a refugee or granted asylum).

E-Verify Statement

Varda Space Industries, Inc. participates in the U.S. Department of Homeland Security E‑Verify program. The E‑Verify program is an Internet-based employment eligibility verification system operated by the U.S. Citizenship and Immigration Services. Learn more about the E‑Verify program.

E-Verify Notice Right To Work Notice

Varda Space Industries is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. Candidates and employees are always evaluated based on merit, qualifications, and performance. We will never discriminate on the basis of race, color, gender, national origin, ethnicity, veteran status, disability status, age, sexual orientation, gender identity, martial status, mental or physical disability, or any other legally protected status.