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Varda Space

In-orbit manufacturing with reentry return services

Principal Materials and Process Engineer

Materials & StructuresUpdated on Nov 13
Full-timeEl Segundo, CA, USA

About the Job

Requirements

  • A B.S. in Materials Science, Metallurgical, Chemical, Mechanical, or a related engineering discipline, or equivalent experience (typically 6–10+ years).
  • At least 6 years in process and materials engineering in aerospace, semiconductor, or another high-reliability industry.
  • A proven record developing and qualifying processes and materials for flight or safety-critical hardware, including first article builds and compliance with standards such as AWS, AMS, or ASTM.
  • Experience authoring and releasing specifications, design guidance, acceptance criteria, and drawing callouts for internal teams and suppliers.
  • Experience with thermal, chemical, mechanical, and non-destructive evaluation (NDE) characterization, including interpreting results to define process windows.
  • Deep expertise in at least one area: ablatives/thermal protection systems (TPS), composites, polymers/adhesives, coatings/surface treatment, wet chemical processing/corrosion control, welding metallurgy, heat treat, additive, or NDE.
  • Experience with aerospace metals, including stainless steel, aluminum, titanium, and nickel alloys, and their processing, including heat treatment, welding, brazing, and finishing.
  • Knowledge of corrosion mechanisms, including galvanic, crevice, pitting, stress corrosion, and hydrogen embrittlement, and material compatibility with process fluids and service environments.
  • Experience developing and controlling wet chemical processes, including bath chemistry, rinse and water quality, precision cleaning and cleanliness verification, and handling hazardous, reactive, or oxidizing fluids.
  • Proficiency in applied statistics, including design of experiments (DOE), statistical process control (SPC), process capability, measurement system analysis (MSA), regression, and statistical tolerancing; experience establishing statistically based material allowables, acceptance criteria, and sampling plans such as A-basis and B-basis.
  • Experience leading root cause and corrective action (RCCA), failure analysis, and material dispositions, including selecting and interpreting lab methods such as fractography, metallography, scanning electron microscopy/energy-dispersive X-ray spectroscopy (SEM/EDS), and chemical analysis, and running cross-functional investigations.
  • Experience developing control plans and special processes, and leading process failure mode and effects analyses (PFMEAs).
  • Experience setting materials and processes requirements for the space environment, including outgassing, contamination control, electrical bonding/grounding, thermal cycling, and ultraviolet (UV) exposure.
  • Strong technical writing, including specifications, test reports, and investment cases.
  • Ability to make sound decisions quickly without established infrastructure, influence material decisions owned by other teams, and hire and mentor engineers.
  • Ability to regularly lift 25 pounds, bend, stoop, and stand for extended periods while working directly with flight hardware.

Responsibilities

  • Establish, qualify, and maintain special processes for flight hardware, including ablative and thermal protection systems, coatings, polymers, composites, adhesives, and metallic structures.
  • Engineer and control wet chemical processes such as cleaning, etching, passivation, and conversion coating.
  • Implement corrosion prevention and control practices, and assess chemical compatibility among materials, process fluids, and service environments.
  • Design experiments, test methodologies, and pathfinder hardware to de-risk new processes; characterize results through mechanical, thermal, chemical, and microstructural testing; and apply statistical methods to define process windows.
  • Define tooling, fixtures, test equipment, cleanliness, contamination control, and material handling requirements for assigned processes and hardware.
  • Author and maintain Special Process Specifications, Process Qualification and Validation Records, and Control Plans.
  • Lead and support root cause and corrective actions, material review boards (MRB), and failure review boards for material and process non-conformances, including corrosion, surface contamination, and defects found in NDE, testing, or inspection; perform failure analysis using fractography, metallography, SEM/EDS, and chemical analysis in-house or through partner laboratories.

Desired Qualifications

  • An M.S. or Ph.D. in Materials Science, Chemical Engineering, or a related discipline, or AMPP/NACE certification.
  • Ablative, thermal protection, and thermal barrier materials for reentry, hypersonic, or propulsion applications, including characterization such as arc jet, thermal conductivity, recession, and char behavior.
  • Polymer and composite processing at scale, including cure cycle development, cure kinetics, and void and porosity control.
  • Spacecraft thermal control and finishing systems, including MLI films, metallizations, anodizing per MIL-A-8625, conversion coating per MIL-DTL-5541, plating, and fluoropolymer coatings, and their effects on bonding and outgassing.
  • High-test peroxide (HTP) systems, including compatibility classes, passivation and conditioning, stabilizer and contaminant effects, catalyst bed materials, active-oxygen-loss testing, decomposition modeling, and diagnosing elevated decomposition or corrosion through propellant assay and trace-metal analysis.
  • Other strong oxidizers and hypergols, including liquid oxygen (LOX), nitrous oxide (N2O), nitrogen tetroxide/mixed oxides of nitrogen (N2O4/MON), and hydrazines; oxygen-service cleaning standards such as ASTM G93, G88, and IEST-STD-CC1246; and oxidizer-compatible polymers, elastomers, and lubricants such as PTFE, PCTFE, FKM/FFKM, PEEK, dry-film, and galling-resistant pairs.
  • Designing, qualifying, or specifying wet process lines and high-purity water systems, including waste handling and environmental, health, and safety (EHS) compliance.
  • Pharmaceutical or bioprocess materials, including product-contact selection, ASME BPE, extractables and leachables, USP Class VI/ISO 10993, cleaning validation, and potent-compound containment.
  • Developing accelerated corrosion test programs and correlating results to service environments.
  • Advanced statistical methods, including Bayesian, mixed-effects, Weibull, and Monte Carlo methods, and advanced characterization such as X-ray diffraction (XRD), computed tomography (CT), and X-ray photoelectron spectroscopy (XPS).
  • Scaling processes to production build rates and qualifying and auditing special-process suppliers, including NADCAP or similar.
  • Building a process and materials function, including an approved materials and processes list, a materials usage agreement process, and an in-house materials laboratory.
  • Recognized subject-matter expertise, with a record of setting technical direction and standards beyond a single program, including cross-discipline chief-engineer or standards roles, publications, patents, or standards-committee participation.

About the Company

Varda Space

In-orbit manufacturing with reentry return services

Varda Space Industries provides in-space manufacturing by operating production facilities in low Earth orbit and returning finished goods to Earth using reentry capsules. Clients send materials or designs to Varda’s in-orbit production line, where microgravity enables manufacturing processes not possible on Earth. After production, capsules re-enter Earth's atmosphere to deliver goods back to customers, supported by in-orbit equipment and reliable reentry systems. The company aims to make low Earth orbit accessible for multiple industries by building end-to-end space manufacturing infrastructure and industrializing orbit for commercial use.

Company size
201-500
Company stage
Series D
Total funding
$609.5M
Headquarters
El Segundo, CA
Founded
2020

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