Principal Manufacturing Engineer (Structures)

About This Role

As the Principal Manufacturing Engineer (Structures) at Varda, you will own the manufacturing processes for primary and secondary structural assemblies that form the backbone of our reentry capsules and spacecraft. From composite layup and cure operations to machined metallic substructures and bonded panel assemblies, you will bridge the gap between structural design intent and production reality. You will work shoulder-to-shoulder with structural design engineers and a skilled technician team to drive process discipline, eliminate rework, and steadily increase vehicle build cadence. This is a hands-on role for someone who understands how parts are actually made, not just how they are designed, and who is energized by the challenge of scaling a complex aerospace manufacturing operation.

Responsibilities

• Own manufacturing processes for composite structures (wet layup, prepreg, autoclave/oven cure), machined metallic components, and bonded assemblies
• Develop and maintain detailed work instructions, process specifications, and manufacturing travelers for all structural build operations
• Provide DFM feedback to structural design engineers on composite part design, tooling accessibility, bond joint design, and fastener patterns
• Implement and enforce cleanliness, FOD prevention, and contamination control procedures for composite and bonded structure operations
• Lead non-conformance investigations and root cause corrective actions for structural build defects and materials issues, including dimensional discrepancies and tolerance stackups, coating failures or damage to structure or protective coatings
• Define and procure tooling — drill jigs, assembly fixtures — required to support production scaling
• Refine floor layouts and product flow for structural subassembly work cells to reduce travel time and improve throughput
• Coordinate with supply chain on incoming material inspection requirements for composite materials, adhesives, and structural raw stock

Basic Qualifications

• B.S. in Mechanical or Materials Engineering, or a related discipline, with consideration given to equivalent professional experience (typically 6–10+ years)
• 6+ years of manufacturing experience with structural assembly or manufacturing — Riveted or welded structures, machined metals, or composites and bonded structures
• Strong understanding of structural static loads analysis, mechanical properties of materials and processes used to assemble riveted and bolted structures.
• Hands-on experience assembling and fabricating structural assemblies, such as welding, adhesive bonding, or riveting.
• Ability to read and interpret engineering drawings, GD&T callouts, and structural assembly models
• Experience writing and maintaining manufacturing process documentation and work instructions
• Strong problem-solving skills; able to diagnose structural build defects and drive corrective action through to closure
• 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

• M.S. degree in Mechanical engineering specialized in Materials Science, Structural Analysis, or related discipline, with consideration given to equivalent professional experience
• Experience manufacturing primary flight structures for launch vehicles, satellites, or reentry systems
• Familiarity and strong understanding of dynamic and vibrational loads analysis
• Background in transitioning structural assemblies from R&D/prototype to rate production, including tooling qualification
• Knowledge of and familiarity with the manufacture of aerospace structural materials like aluminum alloys, titanium, and steel in a manufacturing context
• Experience with 3D CAD tools (CATIA, SolidWorks, NX) for tooling design and assembly model review
• Familiarity with first article inspection (FAI) processes and FAIR documentation requirements
• Prior experience at a new-space or defense prime where structural production cadence was actively being increased

Pay Range

• Salary Range: $181,913 - $262,763/per year
• 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