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Varda Space

In-orbit manufacturing with reentry return services

Principal Manufacturing Engineer - Thermal Protection Systems

Manufacturing EngineeringConfirmed live in the last 24 hours
Full-timeEl Segundo, CA, USA

About the Job

Requirements

  • A B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering, or a related discipline, with consideration given to equivalent professional experience (typically 6–10+ years).
  • At least 6 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 such as PICA, AVCOAT, SLA-561, cork composites, ceramic tiles, or equivalent materials.
  • 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, with familiarity with GD&T as applied to complex surface geometries.
  • Experience writing and maintaining manufacturing process documentation for specialized materials operations.
  • Ability to regularly lift 25 lbs., bend, stoop, and stand for extended periods while working directly with hardware.
  • Must be lawfully authorized to work in the United States and qualify as a U.S. person permitted to access export-controlled items: a U.S. citizen, lawful permanent resident, or protected individual.

Responsibilities

  • Own manufacturing processes for thermal protection system production, including ablative tile and 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, and 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, including temperature and humidity, for TPS material storage and processing areas.
  • Assess and procure TPS-specific tooling, including bonding fixtures, tile templates, surface preparation tooling, and handling equipment.

Desired Qualifications

  • Direct experience manufacturing TPS for reentry vehicles, hypersonic glide vehicles, or planetary entry capsules.
  • Familiarity with TPS inspection methods, including visual inspection, tap testing, and NDE methods applicable to bonded ceramic or ablative tiles.
  • Knowledge of TPS material properties, including ablation rates, density gradients, and 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.
  • 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.

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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