Thermal Protection System (TPS) Manufacturing Engineer

About Varda

Low Earth orbit is open for business. Varda is accelerating the development of commercial space infrastructure, from in-orbit pharmaceutical processing to reliable and economical reentry capsules. Varda’s W-Series vehicles are built, designed, and operated by Varda in-house, including the pharmaceutical processing payloads, the capsules, the C-PICA heat shields, and the satellite buses.

From life-saving pharmaceuticals to more powerful fiber optics, there is a world of products used on Earth today that can only be manufactured in space. Varda is accelerating innovation in the orbital economy by creating both the products and infrastructure needed so space can directly benefit life on Earth. Our mission is to expand the economic bounds of humankind.

Our team is uniquely suited to accomplishing this goal, with leadership and staff comprised of veterans from SpaceX, Blue Origin, major pharmaceutical companies and Silicon Valley. Varda was founded in January 2021 by Will Bruey and Delian Asparouhov with significant backing from world class investors including Khosla Ventures, Lux Capital, Founders Fund, Caffeinated Capital, General Catalyst, and Also Capital.

Varda is headquartered in El Segundo, California, where we have offices and a production facility where our vehicles, equipment, and materials are built, integrated, and tested. Varda also has offices in Washington, DC and Huntsville, AL.

Join Varda, and work to create a bustling in-space ecosystem.

About This Role

As a Thermal Protection System (TPS) Manufacturing Engineer at Varda, you will own the manufacturing processes for the ablative and insulative materials that protect our reentry capsules during the most demanding phase of the mission- reentry. TPS manufacturing is one of the most technically specialized disciplines in aerospace, requiring deep expertise in ablative material processing, bonding, tiling, and surface preparation. You will develop and maintain the processes that ensure every capsule's heatshield is built to survive reentry conditions, working at the frontier of materials science and production engineering. This is a rare opportunity to own a critical, high-visibility manufacturing domain at a company that is already demonstrating reentry capability on orbit. This role is open at the L2 and Senior level, with levels determined based on candidate experience.

Responsibilities

Own manufacturing processes for thermal protection system production: ablative tile/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; 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 (temperature, humidity) for TPS materials storage and processing areas

Assess and procure TPS-specific tooling: bonding fixtures, tile templates, surface preparation tooling, and handling equipment

Basic Qualifications

B.S. in Materials Science, Mechanical, Aerospace, Chemical, or Manufacturing Engineering, or a related discipline, with consideration given to equivalent professional experience (typically 3–6+ years)

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, or equivalent

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; familiarity with GD&T as applied to complex surface geometries

Experience writing and maintaining manufacturing process documentation for specialized materials operations

Must be physically able to regularly lift 25 lbs., bend, stoop, and stand for extended periods while working directly with hardware

Preferred Skills and Experience

Direct experience manufacturing TPS for reentry vehicles, hypersonic glide vehicles, or planetary entry capsules

Familiarity with TPS inspection methods: visual inspection, tap testing, NDE methods applicable to bonded ceramic or ablative tiles

Knowledge of TPS material properties — ablation rates, density gradients, 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 is a strong plus

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

Pay Range

Salary Range:

Eng II: $119,543-$152,749

Senior: $140,333-$179,314

This role is on-site in El Segundo, CA

Leveling and base salary is determined by job-related skills, education level, experience level, and job performance

You will be eligible for incentives in the form of stock options and/or long-term cash awards

Benefits

Consider your benefits covered for launch. At Varda, we invest in benefits and perks that support your health, financial well-being, and life beyond work. Benefits vary by position, with packages designed specifically for our regular full-time employees and interns.

Regular Full-Time Positions:

Health & Wellness

Flexible PTO policy + 12 paid holidays

100% company-paid Medical, Dental, and Vision insurance plans for employees and dependents with FSA and employer-matched HSA options

Voluntary accident, hospital, critical illness, and pet insurance

$120/month wellness reimbursement for gym and fitness expenses

12 weeks of parental leave (with supplemental disability leave for CA mothers)

Family building, pregnancy, parenting and menopause benefits via Maven Clinic

Sponsored One Medical memberships for employees and their dependents

Financial & Retirement

Substantial incentive equity in a fully funded space start-up

401(k) retirement plan with 6% employer match (immediately vested)

$20/pay period cell phone reimbursement

Relocation support for new hires, if needed

Workplace Experience & Perks

Fully stocked kitchen with lunch provided daily and dinner provided twice weekly

Company and team-bonding events, happy hours and mission-success celebrations

Complimentary EV charging

Benefits for Internship Positions:

Health & Wellness

Paid observed holidays.

100% company-paid Medical, Dental, and Vision insurance plans for employees and dependents with FSA and employer-matched HSA options.

$120/month wellness reimbursement for gym and fitness expenses.

Sponsored One Medical memberships for employees and their dependents.

Financial

$20/pay period cell phone reimbursement.

Up to $4,000 gross up in relocation support, if eligible

Up to $850 commute credit through Lyft or car rental reimbursement, if eligible.

Workplace Experience & Perks

Fully stocked kitchen with lunch provided daily and dinner provided twice weekly

Company and team-bonding events, happy hours and mi