Senior Manufacturing Engineer; Structures

Company Overview

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 in-house, including pharmaceutical processing payloads, reentry capsules, C-PICA heat shields, and satellite buses. From life-saving pharmaceuticals to powerful fiber optics, Varda creates products that can only be manufactured in space and expands the economic bounds of humankind.

Senior Manufacturing Engineer (Structures). Own the manufacturing processes for primary and secondary structural assemblies that form the backbone of reentry capsules and spacecraft. Work with structural design engineers and technicians to drive process discipline, eliminate rework, and increase vehicle build cadence. Hands‑on role for someone who understands actual manufacturing, not just design.

• 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 material issues, including dimensional discrepancies, tension 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.

• B.S. in Mechanical or Materials Engineering, or related discipline, with consideration for equivalent professional experience (typically 3–6+ years).
• 3+ years of manufacturing experience with structural assembly or manufacturing (riveted or welded structures, machined metals, composites, or 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.

• M.S. degree in Mechanical Engineering specialized in Materials Science, Structural Analysis, or related discipline, with consideration for 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 aerospace structural materials such as aluminum alloys, titanium, and steel in a manufacturing context.
• Experience with 3D CAD tools (CATIA, Solid Works, 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 increased.

• Salary Range:
  Senior: $140,333 – $179,314 per…