Structures Design Reliability Engineer

Vast is looking for a Structures Design Reliability Engineer, reporting to the Director of Design Reliability, to guide the design, verification, and validation of Haven-1, the world's first commercial human-rated space station.

As a Structures Design Reliability Engineer, you will ensure primary and secondary structures on Haven-1 are appropriately designed and function reliably, without failure, over their intended lifespan by integrating reliability principles directly into the design process. You will drive Failure Modes and Effects Analysis (FMEA), guide test plan definition and review verification & validation data, and facilitate design teams to prevent failures before manufacturing. You will work closely with hardware teams to ensure build practices meet design intent, define test methodologies, and analyze field data to improve design robustness. You will be responsible for shepherding the Haven-1 structure through detailed design and transitioning the space station from design, to a built and tested station ready to host humans in space.

Responsibilities:

• Technical Leadership: Guide design of primary and secondary structures on a large scale space station.
• Cultivate Vast's understanding of static and dynamic loads, vibrations, thermal and other environmental considerations to drive design decisions.
• Lead the technical reviews providing clear, decisive guidance of mechanical design and analysis, manufacturing drawings, test plans, concept of operations, during milestone design reviews and major risk gates.
• Provide critical peer review and approval of hardware designs during design reviews, and of acceptance and qualification test campaigns
• Ensure that the Vasts design process & design criteria/requirements are being followed for flight, launch, and ground support systems.
• Set the standard for acceptance and qualification test completeness for flight systems, ensuring our test campaigns are robust, disciplined, and aligned with human-rated reliability.
• Bring deep engineering intuition to test campaigns, identifying risks early and helping teams converge on safe, resilient solutions.

• Design Excellence: Architect Vast’s structures engineering standards, design guides, and review frameworks; build tools that enable fast, confident decision-making at all levels across the company.
• Develop design criteria, requirements, and verification approaches to support haven-1 design architecture
• Make engineering best practices accessible and actionable, especially for engineers moving rapidly under ambitious program timelines.
• Support and elevate engineering teams across the organization by bringing broad experience in design, build cycles, integration, and test.
• Turn organizational knowledge into lasting guidance by capturing lessons learned and strengthening future standards.

• Process Ownership:Build and steward the processes that ensure engineering rigor at scale—ensuring designs meet standards, reviews are comprehensive, and changes are consistently implemented.
• Own and continuously refine design review templates, reliability checklists, and internal design guides.
• Track design maturity and compliance across the station and vehicle architecture, ensuring nothing slips through the cracks.
• Build tools, frameworks, and automation that empower engineers to explore design trade-offs and risks with clarity and speed.

• Change and Configuration management:Work across all facets of the engineering organization to improve vehicle reliability.
• Partner with configuration and change management so that every update to flight hardware is intentional, reviewed, and fully understood.
• Drive technical trades for the vehicle and enable decisions backed by strong physics based engineering rational
• Coordinate between Change Management, Risk, and Engineering teams to ensure design revisions drive continuous improvement on the vehicle
• Partner with the internal software team to ensure system data, configuration details, and design decisions are well organized and accessible.

• Risk Management:Partner with the Risk management team to identify Risk, and drive design improvements with engineering to mitigate.
• Work with Risk Management and Engineering to quantify Risk and failure probability through rigorous engineering rational
• Drive FMEA and Fault tree analysis across all engineering systems to identify and drive down risk
• Drive best practices for traceability and verification & validation of design revisions to thoroughly document risk mitigations across flight, launch, and ground support systems.

Minimum Qualifications:

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Physics, or related Engineering discipline
• 6+ years of related professional work experience in responsible engineering, design ownership, systems integration, test engineering, or reliability-focused development.

Preferred Skills & Experience:

• 10+ years of related professional work experience in responsible engineering, design ownership, systems integration, test engineering, or reliability-focused development.
• Experience in Responsible Engineering, Systems Engineering, Office of the Chief Engineer, or Reliability Engineering roles on complex aerospace systems.
• Hands-on experience designing, assembling, integrating, or testing hardware.
• Background with spacecraft, aircraft, launch vehicles, or other mission- or safety-critical systems.
• Familiarity with fracture control, reliability methodologies, or human-rated hardware standards.
• Experience creating engineering standards, review templates, or technical guidance frameworks.
• Strong scripting and data analysis skills (Python, MATLAB, Excel) and familiarity with visualization tools (e.g., Tableau).
• Knowledge of manufacturing processes, materials selection, and hardware qualification pathways.
• Strong systems-level intuition and the ability to anticipate and articulate risks early.

Additional Requirements:

• Willingness to work overtime, or weekends to support critical mission milestones.