Principal Thermal Protection System Engineer (TPS)

Principal Thermal Protection System Engineer (TPS)

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

The return lane isn’t going to build itself. Come build it with us.

Outpost is an orbital logistics company rewriting the rules of global logistics by building reusable Earth-return vehicles that unlock in-space manufacturing, on-orbit warehousing, and 60-minute global delivery through space.

Our CarryAll vehicle family returns payloads ranging from 200 kilograms to 10 metric tons, lands within 10 meters of its target, and can then be refurbished and launched again. One vehicle, many missions: responsive logistics and precision delivery for national security; commercial cargo moved with real cadence; R&D payloads flown, tested, and refined across repeatable cycles; and critical aid delivered where roads and runways can’t reach.

The demand is already here, validated through defense and civil agreements and supported by a growing pipeline of government and commercial customers.

We have the customers, the team, and a clear technical path ahead of us. We’re building the return lane. Come build it with us.

The Role 

The Principal Thermal Protection System Engineer (TPS) will lead the design, analysis, and implementation of the (TPS) for 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 reentry, 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 

• Define the Thermal Protection System architecture and thermal protection strategy for the Carryall vehicle, selecting materials and material stack-ups that balance thermal performance, mass, and mechanical flexibility.
• Support and work alongside our aerothermal dynamics team to guide high-fidelity aeroheating analysis (CFD) and thermal response modeling to validate specifications and predict performance under reentry loads.
• Lead the testing and characterization of flexible and rigid TPS materials, including arc-jet testing, radiant heat testing, and mechanical load testing.
• Oversee the transition from theoretical design to flight hardware, managing vendor relationships for TPS materials including fabrics, thermal barriers, and adhesives.
• Develop and support the verification plan for the TPS subsystem, ensuring all requirements are met prior to flight.
• 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.
• Working knowledge of heat transfer mechanisms (convection, radiation, conduction) specifically during atmospheric entry.
• 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)
• 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 & Benefits 

• Competitive compensation: $230,000- $270,000; (commensurate with experience). 
• Additional Compensation:  Annual performance-based bonuses that reward your impact.
• Shared upside: Meaningful equity in Outpost so you share directly in the value you help create.
• Comprehensive healthcare: Medical, dental, and vision coverage to keep you and your loved ones covered. We cover the base tier of medical insurance and all premiums of vision and dental. 
  
• Protection when it matters: Company-provided short- and long-term disability coverage for peace of mind, plus life insurance for even more security.
• PTO: Recharge on your own terms with paid time off, plus 9 days of paid holidays.
• Invest in your future: 401(k) with company match to help you build long-term wealth.
• Fueled for the mission: Daily DoorDash lunch stipend, plus unlimited snacks, coffee, and tea to keep you energized.
• Mission that matters: Work shoulder-to-shoulder with leaders from aerospace, new space, and deep-tech industries building the future of orbital infrastructure.
• Pet Friendly Office: Bring your furry friend into the office so that they can be a part of our mission too.
• Monthly Company Happy Hours and Events: Drinks at the local bar, hibachi nights, mini golfing and more!