Senior Mechanical Engineer - Thermal Protection Systems

Key Responsibilities

• Execute end-to-end ownership of TPS components and subassemblies, from initial requirements definition through final hardware delivery.
• Own and drive material trade studies that balance thermal survivability, structural integrity, and manufacturing realities for hypersonic regimes.
• Collaborate cross-functionally with aerothermal, design, materials, and test groups to translate heat flux and aero loads into robust mechanical designs.
• Develop detailed CAD, drawings, ICD’s, interface directly with the manufacturing floor, and ensure parts are built to spec.
• Support rigorous testing campaigns such as arc-jet, rapidly perform raw data reduction, and draw actionable conclusions to iterate designs based on empirical data.
• Serve as the resident SME in the TPS space, maintaining robust knowledge of current state-of-the-art and next-generation technologies.
• Lead technical sections of proposals and new products that enhance the organization's technical capabilities and support strategic defense growth objectives.

Required Qualifications

• 4+ years of direct, verifiable experience designing and owning TPS components or assemblies qualified through flight or high-enthalpy testing (e.g., arc-jet facilities such as NASA Ames, AEDC).
• Comprehensive knowledge of TPS materials and architectures, including thermal blankets, ablative carbon composites, rigid ceramics, and cryogenic insulation for re-entry and hypersonic environments.
• Full lifecycle design experience taking hardware from concept through manufacturing, including 3D CAD modeling, drawing release, and GD&T application.
• Strong technical foundation in structural mechanics, materials science, thermodynamics, heat transfer, and ablation mechanics.
• Demonstrated track record of delivering hardware on accelerated schedules through pragmatic, creative engineering solutions.
• Strong interdisciplinary communication skills, with the ability to clearly convey complex technical concepts across cross-functional teams.
• U.S. Security Clearance Eligibility: Active Secret clearance (or higher), or the ability to obtain and maintain one, including meeting U.S. government background and export-control requirements

Preferred Qualifications

• Graduate degree in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related technical field.
• Flight Heritage: Direct ownership of a TPS system that successfully operated and survived in a flight environment.
• Systems Experience: Direct experience working on the design, test, or integration of re-entry systems, launch vehicles, or hypersonic platforms.
• Programmatic Acumen: Experience planning and estimating complex projects, constructing bids and Basis of Estimates (BOEs), and developing technical schedules that were successfully executed.
• Business Development: Proven track record of writing and winning IRAD and/or CRAD proposals.
• Customer Facing: Experience interfacing directly with government (DoW, NASA) and commercial customers to define requirements and deliver technical updates.
• Supply Chain Command: Experience and high comfort level interfacing with, auditing, and managing suppliers specifically within the TPS and advanced materials space.
• Strong background operating within the defense sector.
• Familiarity with space and defense standards such as but not limited to SMS-S-016, MIL-STD-810, NASA-GSFC-7000 series or other industry equivalent standards for design, analysis, and testing of defense articles.

Additional Requirements

• Ability to work in office, lab, and manufacturing environments with occasional exposure to noise, dust, and temperature variations.
• Must be able to lift and carry up to 35 lb and perform tasks involving standing, walking, bending, and manual assembly.
• Visual acuity required for reading technical drawings, inspecting components, and operating precision instruments.
• Occasional travel to customer or test sites, including outdoor or industrial settings, with adherence to company and OSHA safety protocols.
• Must have professional working proficiency reading, writing, and speaking English.

Job Details

Salary Range: $130,000 - $180,000
FLSA Classification: Salary Exempt
Type: Full Time
Base Location: Irvine, CA
Travel: Up to 25%