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%