Process Engineer (Propulsion)

Hypersonica; Greater London; Hybrid; GBP 65,000 - 95,000; Full time

Benefits offered by this job

Share options

Job summary

Hypersonica is seeking a Manufacturing Engineer to define and optimise the end-to-end manufacturing pathway for rocket motors. You will plan layouts, ensure safety compliance from the start, and apply PFMEA, Control Plans and PPAP to create robust, scalable processes.

This role involves hands-on shop floor work across trials to production, in a small, autonomous team. You will work in a mission-driven environment focused on Europe’s defence capability, balancing rigorous engineering with startup

Qualifications

• Manufacturing engineer with experience in high‑volume explosive materials.
• Experience in Manufacturing Engineering within an ISO 9001 environment.
• Skilled in PFMEA, Control Plans, and PPAP; able to apply from scratch.
• Experience defining processes in COSHH, ITAR, and COMAH compliance.
• Understand how process design affects safety, throughput and compliance.
• Balance engineering rigor with startup speed in a small team.

Responsibilities

• Define end-to-end manufacturing pathway for rocket motor, from parts reception to delivery.
• Plan optimal sequence and layout to minimise wait times and keep flow of material.
• Ensure manufacturing complies with safety legislation from the outset.
• Apply PFMEA, Control Plans, and PPAP to build robust processes.
• Own COSHH, ITAR, and COMAH compliance within the design process.
• Hands-on shop floor work from early trials to full-rate production; support builds.

Skills

PFMEA

PPAP

Control Plans

COSHH

ITAR

COMAH

ISO 9001

Safety compliance

Job description

Help Build Europe's Hypersonic Capability

At Hypersonica, we’re redefining what’s possible in European defence technology. We exist to deliver speed, resilience, and technological independence at a pace that sets a new standard. We are a small, elite team working on problems that matter, and solving them fast.

By joining Hypersonica, you’re not stepping into a predefined role. You’re joining a talent dense environment where every individual shapes the direction of the company. Our philosophy is to hire a small number of exceptional people with broad, deep technical capability, strong judgement, and the ability to operate autonomously.

We hire for talent, not rigid boxes. This role represents a business need, but the way it evolves will be shaped by the individual. If you’ve achieved what others said was impossible, or you bring a unique combination of skills that doesn’t fit a traditional mould, we want to hear from you. The work you do here directly contributes to Europe’s technological independence.

What you’ll do

• Define the end-to-end manufacturing pathway for the rocket motor, from reception of hardware through to delivery of the completed motor, owning the process from first principles.
• Plan the optimal sequence and layout of operations to minimise component waiting time and keep material flowing efficiently through the site.
• Define how the manufacturing process remains compliant with safety legislation, establishing this early so it shapes the process rather than constraining it after the fact.
• Apply Process Failure Mode and Effect Analysis (PFMEA), Control Plans, and Production Part Approval Process (PPAP) to build robust, repeatable manufacturing processes.
• Own compliance to COSHH, ITAR, and COMAH within the manufacturing process design, working closely with safety, quality, and engineering teams.
• Work hands-on across the shop floor, from early process trials through full-rate production, supporting build, troubleshooting, and continuous improvement.
• Partner closely with propulsion, quality, and safety teams to ensure manufacturing processes are safe, compliant, and ready to scale.
• Use production feedback to continuously refine processes, eliminate bottlenecks, and reduce risk.

Who you are

• A manufacturing engineer with experience in high volume manufacturing of explosive materials.
• Experienced in Manufacturing Engineering within an ISO 9001 environment.
• Skilled in PFMEA, Control Plan, and PPAP, and comfortable applying them to define new processes from scratch.
• Experienced defining processes in compliance with COSHH, ITAR, and COMAH legislation.
• Someone who understands how process design decisions show up in safety, throughput, and compliance, and designs accordingly.
• Able to balance engineering rigour with startup speed, making sound decisions with incomplete data.
• Motivated by building core capability from the ground up in a small team where your processes directly affect production success.
• Energised by responsibility, ownership, and seeing your work move from concept to full-rate production.

Security and Elibigility Requirement

Due to the nature of the work with the UK MOD, applicants must be a British Citizen (or Dual UK national with British citizenship) and eligible for UK Security Clearance (SC) and, whererequired, Developed Vetting (DV)

What we offer

• A mission driven environment with the opportunity to work on one of Europe's most consequential defence challenges, with direct impact on sovereign capability and security.
• Daily collaboration with top experts across engineering, operations, and defence, with real opportunity to learn from the best, contribute, and grow.
• High ownership and autonomy; no time tracking, no micromanagement, just clear objectives and accountability for outcomes.
• A fast paced environment where good ideas are implemented quickly, and feedback from production drives real decisions.
• A culture that values clarity, integrity, and excellence, and supports people who take initiative and push boundaries responsibly.
• Competitive compensation and real share options aligned to responsibility and impact, not tenure or hierarchy.

Hypersonica is an equal‑opportunity employer and assesses candidates solely on merit, capability, and potential.