Materials Engineer II, Off-Planet Systems

ICON is seeking a Materials Engineer to join our Strategic R&D team, with a focus on developing 3D-printable materials using lunar and Martian regolith. This role will drive the research, development, and testing of in-situ resource utilization (ISRU) materials that replace traditional concrete with regolith-based composites to enable sustainable construction beyond Earth. You will lead materials formulation and testing, develop standards and quality protocols for off-planet construction, and collaborate with cross-functional teams to create viable, high-performance solutions for extraterrestrial habitats. This position is based in Austin, TX and reports to the Senior Director of Off-Planet Systems.

RESPONSIBILITIES

• Lead the formulation, testing, and optimization of 3D-printable, regolith-based composites for lunar and Martian construction applications.
• Develop and implement testing programs to evaluate physical, chemical, and mechanical performance of regolith-derived materials under simulated planetary conditions.
• Build a materials development roadmap aligned with ICON's off-planet construction goals, including standards for testing, application, and quality control.
• Characterize regolith simulants and their performance in binder systems (e.g., sulfur, geopolymer, sintering, polymer, or other ISRU-compatible methods).
• Support design and validation of planetary regolith handling, preparation, and delivery systems in coordination with robotics and mechanical teams.
• Collaborate with internal engineers, mission partners, and academic researchers to guide materials innovation based on evolving mission requirements.
• Document findings in technical reports, material specification sheets, and peer-reviewed studies.
• Provide mentorship and technical guidance to junior engineers, interns, and lab technicians.

MINIMUM QUALIFICATIONS

• Master's degree in Materials Science, Civil Engineering, Geomaterials, Ceramics, or a related field with a focus on non-traditional or extreme-environment materials.
• 5+ years of experience in material development, with hands-on work in composites, ceramics, geopolymers, or cementitious systems.
• Strong knowledge of mechanical behavior, rheology, and curing mechanisms of particulate or mineral-based materials.
• Experience with ASTM, ACI, or related materials testing standards and protocols.
• Ability to design and run experiments for structural and environmental validation of new materials.

PREFERRED SKILLS & EXPERIENCE

• Experience developing materials for ISRU, planetary regolith simulants, or space analog environments.
• Familiarity with geopolymer chemistry, sintered regolith, sulfur-based concrete, or ceramic composites.
• Understanding of environmental constraints in lunar or Martian construction, such as vacuum, temperature swings, and radiation.
• Hands-on experience with extrusion-based or additive manufacturing technologies.
• Experience working in multi-disciplinary teams with robotics, planetary science, and aerospace engineering functions.