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Varda Space Industries is building commercial space infrastructure, including in-orbit pharmaceutical processing systems and reentry capsules with advanced thermal protection systems. As a Thermal Protection System (TPS) Manufacturing Engineer, you will own the end-to-end manufacturing processes for ablative and insulative materials that protect reentry capsules during the most demanding phase of spaceflight—atmospheric reentry.
This is a specialized role at the intersection of materials science and production engineering. You will develop and maintain manufacturing processes for TPS production, including ablative tile/panel preparation, bonding, densification, and closeout operations. Key responsibilities include:
- Owning manufacturing processes for thermal protection system production and developing detailed work instructions, process travelers, and process specifications
- Implementing surface preparation, adhesive application, and cure cycle procedures that meet TPS bond strength and thermal performance requirements
- Collaborating with TPS design engineers to provide design-for-manufacturability feedback on tile geometry, bond joint design, and tooling access
- Defining inspection and verification methods for TPS bonds, surface finish, and dimensional conformance; integrating quality gates into production workflows
- Leading root cause analysis and corrective actions for TPS non-conformances, including bond voids, tile cracking, and surface contamination
- Developing and controlling environmental conditioning requirements for TPS materials storage and processing areas
- Assessing and procuring TPS-specific tooling, including bonding fixtures, tile templates, and handling equipment
You will need a B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering (or equivalent professional experience), plus 3+ 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 (PICA, AVCOAT, SLA-561, cork composites, ceramic tiles) is essential. You must be comfortable reading engineering drawings, interpreting GD&T for complex geometries, and writing manufacturing process documentation. Physical ability to regularly lift 25 lbs. and work directly with hardware is required.
Preferred experience includes direct TPS manufacturing for reentry vehicles, hypersonic glide vehicles, or planetary entry capsules; familiarity with TPS inspection methods (visual inspection, tap testing, NDE); and knowledge of TPS material properties including ablation rates, density gradients, and outgassing behavior.
Varda is headquartered in El Segundo, California, with offices and a production facility where vehicles, equipment, and materials are built, integrated, and tested. The company also has offices in Washington, DC and Huntsville, AL. Founded in 2021 by Will Bruey and Delian Asparouhov, Varda is backed by leading investors including Khosla Ventures, Lux Capital, Founders Fund, and General Catalyst. The team includes veterans from SpaceX, Blue Origin, major pharmaceutical companies, and Silicon Valley.
