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Varda Space

In-orbit manufacturing with reentry return services

Senior 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 demonstrated equivalent expertise.
  • At least 3 years of process and materials engineering experience in aerospace, semiconductor, or another high-reliability industry.
  • A track record of developing and qualifying processes and materials for flight or safety-critical hardware, including first article builds and compliance with industry standards such as AWS, AMS, or ASTM.
  • Deep expertise in at least one area: ablatives and thermal protection systems, composites, polymers and adhesives, coatings and surface treatment, wet chemical processing, welding metallurgy, heat treat, additive manufacturing, or nondestructive evaluation.
  • Working knowledge of aerospace metals, including stainless steel, aluminum, titanium, and nickel alloys, and their heat treatment, welding, brazing, and finishing.
  • Command of corrosion mechanisms, including galvanic, crevice, pitting, stress corrosion, and hydrogen embrittlement, and chemical compatibility of materials with process fluids and service environments.
  • Hands-on development and control of wet chemical processes, including bath chemistry, water quality, precision cleaning, cleanliness verification, and handling hazardous, reactive, or oxidizing fluids.
  • Skill in thermal, chemical, mechanical, and nondestructive evaluation characterization, including interpreting results to define process windows.
  • Proficiency in applied statistics, including design of experiments, statistical process control, process capability, measurement system analysis, regression, and statistical tolerancing; establishing material allowables such as A-basis and B-basis, acceptance criteria, and sampling plans.
  • Experience leading root cause and corrective actions, failure analysis, and material dispositions, including selecting and interpreting laboratory methods such as fractography, metallography, scanning electron microscopy/energy-dispersive X-ray spectroscopy, and chemical analysis, and driving cross-functional investigations.
  • Background developing control plans and special processes, and leading process failure mode and effects analyses.
  • Experience authoring specifications, design guidance, acceptance criteria, and drawing callouts released to internal teams and suppliers.
  • Familiarity with setting materials and processes requirements for the space environment, including outgassing and contamination control, electrical bonding and grounding, thermal cycling, and ultraviolet exposure.
  • Strong technical writing skills for specifications, test reports, and investment cases.
  • Sound, rapid decision-making without established infrastructure, and credibility to influence material decisions owned by other teams and to hire and mentor engineers.
  • Must be physically able 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 board activities, and failure review boards for material and process non-conformances, including corrosion, surface contamination, and defects found in nondestructive evaluation, testing, or inspection; perform failure analysis in-house or through partner laboratories.

Desired Qualifications

  • An M.S. or Ph.D. in Materials Science, Chemical Engineering, or a related discipline.
  • Background in ablative, thermal protection, and thermal barrier materials for reentry, hypersonic, or propulsion applications, including characterization such as arc jet testing, thermal conductivity, recession, and char behavior.
  • Hands-on polymer and composite processing at scale, including cure cycle development, cure kinetics, and void and porosity control.
  • Knowledge of spacecraft thermal control and finishing systems, including multilayer insulation films, metallizations, anodizing to MIL-A-8625, conversion coating to MIL-DTL-5541, plating, and fluoropolymer coatings, and their effects on bonding and outgassing.
  • Experience designing, qualifying, or specifying wet process lines and high-purity water systems, including waste handling and environmental, health, and safety compliance.
  • Depth in high-test peroxide 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.
  • Proficiency with other strong oxidizers and hypergols, including liquid oxygen, nitrous oxide, nitrogen tetroxide/mixed oxides of nitrogen, 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 materials, and galling-resistant pairs.
  • Familiarity with pharmaceutical or bioprocess materials, including product-contact selection, ASME BPE, extractables and leachables, USP Class VI/ISO 10993, cleaning validation, and potent-compound containment.
  • Experience developing accelerated corrosion test programs and correlating results to service environments.
  • Fluency in advanced statistical methods such as Bayesian analysis, mixed-effects models, Weibull analysis, and Monte Carlo methods, and advanced characterization such as X-ray diffraction, computed tomography, and X-ray photoelectron spectroscopy.
  • A track record of scaling processes to production build rates and qualifying and auditing special-process suppliers, such as NADCAP suppliers.
  • A history of 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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