Senior Thermal Protection System Engineer (TPS)

Sr. Thermal Protection System Engineer 

Sr. Thermal Protection System Engineer 

Location: Playa Vista, California (in-person, five days per week) 

Outpost is pioneering Earth return logistics for space. We're building vehicles that can return payloads from orbit safely and precisely enabling faster space-based manufacturing, global delivery, and entirely new capabilities in the space economy. Our spacecraft is already backed by the U.S. government with multiple missions ahead. We're a mission-focused team, building with urgency, grit, and care for the work we do and the people we do it with. 

The Role 

The Sr. Thermal Protection System Engineer (TPS) will lead the design, analysis, and implementation of the critical heat shield technology for the thermal protection system of our Carryall reentry vehicle. This role sits at the intersection of high-temperature materials science, aerothermal analysis, and mechanical design. You will own the primary barrier that allows our vehicles to survive the extreme environments of re-entry, turning the "impossible" physics of returning from orbit into a repeatable, reusable operation. 

You will work closely with engineering leadership and the mechanical engineering team, to architect a TPS that is robust enough to handle hypersonic heat fluxes and flexible enough to stow and deploy on orbit. This is a hands-on technical leadership role for someone who is ready to take ownership of a flight-critical subsystem from design through to flight qualification. 

Responsibilities 

• Lead TPS Architecture: Define the thermal protection strategy for the thermal protection system of the Carryall vehicle, selecting materials and stack-ups that balance thermal performance, mass, and mechanical flexibility.
• Aerothermal Analysis: Perform and guide high-fidelity aeroheating analysis (CFD) and thermal response modeling to validate specifications and predict performance under re-entry loads.
• Material Qualification: Lead the testing and characterization of flexible and rigid TPS materials, including arc-jet testing, radiant heat testing, and mechanical load testing.
• Design for Manufacturability: Oversee the transition from theoretical design to flight hardware, managing vendor relationships for TPS materials including fabrics, thermal barriers, and adhesives.
• Validation & Verification: Develop and support the verification plan for the TPS subsystem, ensuring all requirements are met prior to flight.
• Technical Leadership: Mentor junior engineers and contribute to the technical roadmap for future scaled up re-entry vehicle generations 

Qualifications 

• Bachelor's degree or higher in Aerospace, Mechanical, or Materials Engineering (or related field).
• 10+ years of experience in the development of thermal protection systems, hypersonic aerodynamics, or high-temperature structural materials.
• Deep understanding of heat transfer mechanisms (convection, radiation, conduction) specifically during atmospheric entry.
• Simulation expertise: Proficiency with thermal and ablation modeling tools (e.g., FIAT, CMA, Thermal Desktop, or custom solvers) and analysis software (ANSYS, MATLAB/Python).
• Hands-on experience with hardware testing, specifically environmental or arc-jet testing of TPS materials.
• Proven ability to manage complex trade studies involving mass, volume, and thermal performance.
• Strong written and verbal communication skills to articulate complex thermal risks to the broader engineering team.
• Comfortable working in a fast-paced startup environment where requirements may evolve and urgency is key. 

Preferred Experience 

• Active U.S. Government Security Clearance (Not required, but beneficial)
• Experience with Deployable Aerodynamic Decelerators (HIAD/ADEPT) or flexible thermal protection systems for reentry at extreme thermal heat. 
• Direct experience with hypersonic vehicle flight hardware from concept to post-flight analysis.
• Familiarity with government or commercial spaceflight standards (NASA/DoD) for thermal protection.
• Experience in a "Design, Build, Fly" environment with rapid iteration cycles. 

Compensation 

• $160,000 – $210,000; Salary may vary with experience
• Incentive Stock Options
• Annual Performance-Based Bonus Medical, Dental and Vision Insurance
• Short- and Long-Term Disability Insurance
• Life Insurance
• PTO
• 401k with Company match
• Subsidized daily catered lunch, snacks and coffee