Thermal Protection System Technician

Role details

Bevilacqua Research Corporation (BRC) is a Service Disabled Veteran Owned, Small Business based in Huntsville, Alabama incorporated in 1992. BRC provides “best-value” technical and management solutions to a diverse government and commercial customer base in the following key business areas: test & evaluation, systems analysis & integration, security & intelligence, and R&D.

The Non‑Metallic Materials and Space Environmental Effects Team is seeking a hands‑on, detail‑oriented Thermal Protection System (TPS) Technician to support the application, processing, and documentation of aerospace thermal protection materials. This position is a full-time role. This role focuses on performing surface preparation and masking. The technician will follow detailed instructions and procedures while supporting TPS processing in a laboratory environment, contributing directly to flight and development hardware.

Responsibilities

• Conduct surface preparation and masking operations on flight and development hardware to ensure proper material adhesion and quality.
• Operate shop tools and perform light machining required for fixture preparation, sample fabrication, and TPS processing support.
• Follow detailed work instructions, material process specifications, and quality documentation requirements.
• Maintain accurate process documentation, including material traceability, environmental conditions, and equipment usage logs.

Additional responsibilities may include, but are not limited to:

• Apply aerospace insulative spray foams, coatings, and paints following controlled procedures and engineering instructions.
• Perform pour‑foam mixing, dispensing, and curing operations, including mold preparation and adhesive application.
• Assist in setup, operation, and troubleshooting of automated or semi‑automated spray equipment and mixing/dispensing tools.
• Support maintenance of laboratory equipment, consumable tracking, safety compliance, and cleanliness standards.
• Document work performed, recording observations, deviations, and configuration changes with high accuracy.
• Assist engineers with test article preparation, prototype TPS development, and continuous improvement of material processing workflows.

• Typically, educational requirement is a High School diploma or General Equivalency Diploma (GED) or equivalent; candidate must have at least 6 years of experience and continuing education, or an associate’s degree or equivalent and at least 2 years of experience that proves mechanical aptitude and ability to work effectively without direct supervision.
• Hands‑on experience in laboratory, shop, coating, painting, or materials processing environments.
• Ability to follow detailed procedures, safety protocols, and engineering instructions accurately.
• Familiarity with spray systems, adhesives, coatings, or polymer‑based materials, or willingness to learn.
• Experience using measurement tools, basic machining tools, and standard laboratory/shop equipment.
• Basic computer skills and comfort with electronic documentation systems.

• Experience applying aerospace foams, coatings, adhesives, or similar TPS materials.
• Background in coating application, paint booth operation, mask-and-prep work, or polymer processing.
• Prior work involving machining, fixture fabrication, or precision hardware preparation.
• Experience operating automated mixing, spraying, or dispensing equipment.
• Familiarity with non-metallic materials, including foams, polymers, adhesives, and elastomers.

Physical Requirements

• Work is primarily performed in a shop or laboratory environment supporting material processing, machining, and related activities, requiring standing for extended periods and use of appropriate PPE such as safety glasses, safety shoes, and hearing protection.
• Occasional work in full Tyvek (“bunny suit”) protective gear and respirator is required when handling specific foam, coating, or adhesive systems. These tasks may involve elevated heat and physical discomfort, but are broken up into rotational breaks.
• Short periods of sitting at a computer or participating in meetings will also be required.

EEO Policy

Bevilacqua Research Corporation is proud to be an Equal Opportunity Employer. Our hiring practices provide equal opportunity for employment without regard to race, religion, color, sex, gender, national origin, age, United States military veteran’s status, ancestry, sexual orientation, gender identity, marital status, family structure, medical condition including genetic characteristics or information, veteran status, or mental or physical disability so long as the essential functions of the job can be performed with or without reasonable accommodation, or any other protected category under federal, state, or local law.