Energetics Manufacturing Engineer

PDS Defense, Inc.; Culpeper (VA); On-site; USD 110,000 - 140,000; Full time

Job summary

PDS Defense, Inc. in Culpeper, VA is seeking an Energetics Manufacturing Engineer to support energetic materials manufacturing operations and drive process improvements. You will work on integrating new technologies and automation, ensuring safety and regulatory compliance while mentoring junior engineers.

The role requires deep hands-on experience with energetic materials processes, DoD 4145 standards, and collaboration across safety, quality, and operations teams to meet production goals.

Qualifications

• Bachelor's degree in engineering (Chemical/Mechanical/Aerospace).
• Minimum 5 years as a Manufacturing Engineer with energetic materials.
• Experience leading process improvements and implementing manufacturing solutions.
• Experience with automation integration and new process introduction.
• Knowledge of DoD 4145 regulations governing energetic materials storage/handling.

Responsibilities

• Design, develop, and optimize energetic materials manufacturing processes.
• Lead process improvement initiatives to enhance yield and reduce costs.
• Drive integration of new technologies and automation into manufacturing environments.
• Manage NPI activities including process qualification and production readiness reviews.
• Operate, maintain, and troubleshoot energetic processing equipment (e.g., vertical mixers, fluid energy mills).
• Develop SOPs, work instructions, process flow diagrams, and control plans.
• Ensure all activities comply with DoD 4145 and safety standards.
• Collaborate with safety, quality, program management, and operations teams.
• Conduct hazard analyses and risk assessments for energetic materials.
• Mentor junior engineers and production staff.
• Support facility and equipment qualification and validation.

Skills

Energetics manufacturing

Process improvement

Automation integration

NPI management

Hazard analysis

Mentoring

Education

Bachelor's degree in Chemical Engineering

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Aerospace Engineering

Tools

Vertical mixers

Fluid energy mills

Energetic processing equipment

Job description

Engineering

Energetics Manufacturing Engineer Culpeper, VA Posted: 8/5/2026

Job Description

Job ID#:

224544

Job Category:

Engineering

Position Type:

Associate - W2

Shift:

1

PDS Defense, Inc. is seeking an Energetics Manufacturing Engineer, in Culpeper, VA.

Job Description:

We are seeking an experienced Energetics Manufacturing Engineer to join our team. This role is responsible for supporting and advancing energetic materials manufacturing operations, driving process improvements, integrating new technologies and automation, and ensuring compliance with applicable safety and regulatory standards. The ideal candidate brings deep hands‑on experience with energetic materials manufacturing processes and a strong engineering foundation.

Responsibilities :

• Design, develop, and optimize manufacturing processes for energetic materials, ensuring safety, quality, and efficiency standards are met
• Lead and execute process improvement initiatives, identifying opportunities to enhance yield, reduce costs, and improve operational performance
• Drive the integration of new technologies and automation solutions into existing manufacturing environments
• Manage new process introduction (NPI) activities, including process qualification, documentation, and production readiness reviews
• Operate, maintain, and troubleshoot specialized process equipment including vertical mixers, fluid energy mills, and other related energetic processing equipment
• Develop and maintain process documentation including SOPs, work instructions, process flow diagrams, and control plans
• Ensure all manufacturing activities are conducted in compliance with DoD 4145 standards and other applicable safety and regulatory requirements
• Collaborate cross-functionally with safety, quality, program management, and operations teams to support production goals
• Conduct hazard analyses and risk assessments associated with energetic materials processing
• Mentor and provide technical guidance to junior engineers and production personnel
• Support facility and equipment qualification activities, including process validation and acceptance testing

Basic Hiring Criteria :

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Aerospace Engineering, or a closely related engineering discipline
• Minimum 5 years of experience as a Manufacturing Engineer working directly with energetic materials
• Demonstrated experience leading process improvement initiatives and implementing solutions in a manufacturing environment
• Experience with new technology/automation integration and new process introduction
• Working knowledge of DoD 4145 regulations and standards governing the storage, handling, and manufacturing of ammunition and explosives

Desired Qualifications :

• 10 or more years of experience in energetic materials manufacturing engineering
• Hands‑on experience with vertical mixing systems, fluid energy mills, and other energetic materials processing equipment
• Chemical Engineering degree strongly preferred
• Familiarity with explosive safety site plans (ESSPs), quantity‑distance (Q‑D) requirements, and related DoD/DoE safety frameworks
• Experience working within a defense contractor or government manufacturing environment
• Familiarity with Lean Manufacturing, Six Sigma, or other continuous improvement methodologies
• Active DoD Security Clearance or ability to obtain one

Benefits offered to vary by the contract.

Depending on your temporary assignment, benefits may include:

• direct deposit
• free career counseling services
• 401(k)
• select paid holidays
• short‑term disability insurance
• skills training
• employee referral bonus
• affordable medical coverage plan
• DailyPay (in some locations)

For a full description of benefits available to you, be sure to talk with your recruiter.

Job Requirements

Minimum Security Clearance:

Secret

Military connected talent encouraged to apply.

VEVRAA Federal Contractor / Request Priority Protected Veteran Referrals / Equal Opportunity Employer / Veterans / Disabled

To read our Candidate Privacy Information Statement, which explains how we will use your information, please visit http://www.tadpgs.com/candidate-privacy/ or https://pdsdefense.com/candidate-privacy/

The Company will consider qualified applicants with arrest and conviction records in accordance with federal, state, and local laws and/or security clearance requirements, including, as applicable:

• The California Fair Chance Act
• Los Angeles City Fair Chance Ordinance
• Los Angeles County Fair Chance Ordinance for Employers
• San Francisco Fair Chance Ordinance

VEVRAA Federal Contractor / Request Priority Protected Veteran Referrals / Equal Opportunity Employer / Veterans / Disabled