Lead Propellant Manufacturing Engineer, Hypersonic Systems

Castelion; Rio Rancho (NM); On-site; USD 110,000 - 150,000; Full time

Job summary

Castelion seeks a Propellant Manufacturing Engineer to lead solid rocket propellant production for hypersonic programs, overseeing formulation, mixing, casting, and curing in a high-consequence environment.

You will partner with Propulsion Design, Quality, Automation & Controls, and Supply to ensure safety, DoD ITAR compliance, and scalable production, including ramping at Midland, TX and New Mexico facilities.

Qualifications

• 5+ years of manufacturing or process engineering experience in a high-hazard environment.
• Experience developing or scaling mixing, casting, or similar batch processes.
• Hands-on experience with propellant or energetic materials processing.
• Knowledge of rheology, quality attributes, and process sensitivity.
• Familiarity with PFMEA, statistical tools, and data documentation.
• Experience with equipment design/qualification and process validation.

Responsibilities

• Own or lead propellant manufacturing processes, including ingredient prep, batch mixing, vacuum casting, grain forming, curing, and finishing operations.
• Develop, document, and improve process parameters, work instructions, and control plans.
• Execute DFM and PFMEA; drive SPC and yield improvements.
• Support NPI by translating formulation and grain design into scalable processes.
• Perform root-cause analysis and implement corrective/preventive actions.
• Collaborate with Automation & Controls to improve mixing, casting, and handling automation while maintaining safety.
• Ensure compliance with energetic materials handling protocols, DoD 4145.26-M, ATF, ITAR, and site safety standards.
• Support equipment selection, qualification, maintenance, and process validation.
• Interface with suppliers on propellant ingredients and materials; contribute to supplier process improvements.
• Mentor junior engineers and technicians; contribute to training and standardization across sites.
• Support facility ramp and capability expansion at Midland, TX and Project Ranger NM.

Skills

Manufacturing experience

Process engineering

Propellant handling

Statistical tools

PFMEA

Root-cause analysis

Equipment qualification

Data collection

Education

Bachelor's or Master's in Chemical Engineering / Materials Science / Manufacturing / Mechanical Engineering

Tools

Minitab

Job description

Castelion seeks a Propellant Manufacturing Engineer to lead solid rocket propellant production for hypersonic programs, overseeing formulation, mixing, casting, and curing in a high-consequence environment.

You will partner with Propulsion Design, Quality, Automation & Controls, and Supply to ensure safety, DoD ITAR compliance, and scalable production, including ramping at Midland, TX and New Mexico facilities.