Manufacturing Engineer, Propellant Hardware

Front Door Defense; Torrance (CA); On-site; USD 140,000 - 210,000; Full time

Benefits offered by this job

Equity participation

PTO 4 weeks + 10 holidays

Health benefits (medical/dental/vision

Parental leave

Fitness stipend

Onsite EV charging

Catered meals

Job summary

Castelion is seeking a Propellant Manufacturing Engineer to lead scaling of solid rocket motor propellant processes from pilot to high-rate production, ensuring safety, quality, and throughput. You will own mixing, casting, curing, and related operations while collaborating with multiple teams to meet stringent DoD/ITAR standards.

The role requires 5+ years in propellant or energetic materials with hands-on experience in regulated environments, PFMEA/SPC usage, and process documentation.

Qualifications

• Bachelor's or Master's in chemical/related engineering.
• 5+ years in manufacturing/process engineering with 3+ years hands-on propellant or energetic materials.
• Experience scaling mixing/casting/batch operations in regulated environments.
• Hands-on with propellant mixing, vacuum casting, and curing.
• Knowledge of propellant rheology and quality attributes.
• Proficiency with PFMEA, SPC, and process documentation.
• Data collection for batch processes and instrumentation.
• ITAR or energetic materials safety familiarity.

Responsibilities

• Own or lead propellant manufacturing processes across mixing, casting and curing.
• Develop and improve process parameters, work instructions and control plans.
• Run DFM/Process FMEA; drive SPC and yield improvements.
• Support NPI by translating requirements into scalable processes.
• Perform root-cause analysis and implement CAPAs.
• Collaborate with Automation & Controls to improve equipment and safety.
• Ensure compliance with energetic materials safety and regulations.
• Support equipment selection, qualification, maintenance and validation.
• Interface with suppliers for propellant ingredients and materials.
• Mentor junior engineers and contribute to training.
• Assist ramp at Midland, TX and Project Ranger NM sites.

Skills

Propellant manufacturing

Process scaling

Root-cause analysis

Regulated environment

Data analysis

Education

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

Tools

Minitab

PFMEA

SPC

Batch data collection

Job description

Manufacturing Engineer, Propellant

Lead the scaling of propellant manufacturing processes from pilot to high-rate production

Location: Torrance, California

About The Role

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.

This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.

We are seeking a Propellant Manufacturing Engineer to lead and execute propellant manufacturing processes for solid rocket motors (SRM) supporting Castelion's hypersonic strike programs, including Blackbeard. This role focuses on the development, optimization, qualification, and scaling of propellant formulation, mixing, casting, curing, and related processes. You will work hands-on with energetic materials in a high-consequence environment, driving process reliability, yield, safety, and throughput as we transition from prototype and research builds to high-rate production. Partnering closely with Propulsion Design, Manufacturing, Quality, Automation & Controls, and Test teams, you will ensure propellant processes meet stringent performance, safety, and producibility requirements.

Responsibilities

• Own or lead propellant manufacturing processes, including ingredient preparation, batch mixing, vacuum casting, grain forming, curing, and finishing operations.
• Develop, document, and continuously improve process parameters, work instructions, and control plans for propellant production.
• Execute Design for Manufacturability (DFM) and process FMEA activities; drive statistical process control (SPC) and yield improvement initiatives.
• Support new product introduction (NPI) by translating propellant formulation and grain design requirements into robust, scalable manufacturing processes.
• Perform root‑cause analysis and implement corrective/preventive actions for process deviations, defects, or quality issues. Collaborate with Automation & Controls teams to introduce or improve mixing, casting, and handling automation while maintaining strict safety and process control.
• Ensure full compliance with energetic materials handling protocols, DoD 4145.26-M, ATF regulations, ITAR, and site-specific explosive safety standards.
• Support equipment selection, qualification, maintenance, and process validation for mixers, casting systems, ovens, and related tooling.
• Interface with suppliers on propellant ingredients and intermediate materials; contribute to incoming quality and supplier process improvements.
• Mentor junior engineers and technicians; contribute to training programs and process standardization across production sites.
• Support facility ramp and capability expansion at the Midland, TX operations and Project Ranger campus in New Mexico.

Basic Qualifications

• Bachelor's or Master's degree in Chemical Engineering, Materials Science, Manufacturing Engineering, Mechanical Engineering, or related technical field.
• 5+ years of manufacturing or process engineering experience, with at least 3+ years hands‑on work involving solid propellants, energetic materials, or analogous high-hazard chemical/process manufacturing.
• Demonstrated experience developing or scaling mixing, casting, or similar batch/process operations in a regulated environment.
• Hands‑on experience with propellant or energetic mixing (planetary, vertical, or similar mixers), vacuum casting, and curing processes.
• Strong understanding of propellant rheology, ingredient interactions, process sensitivity, and quality attributes (density, voids, mechanical properties, ballistic performance).
• Proficiency with process documentation, statistical tools (Minitab or similar), PFMEA, and root‑cause methodologies.
• Familiarity with process equipment design/qualification, instrumentation, and data collection for batch processes.
• Working knowledge of energetic materials safety, hazardous location requirements, and large-scale chemical handling practices.
• Ability to interpret engineering drawings, specifications, and material data sheets.

Preferred Skills and Experience

• Direct experience manufacturing solid rocket motor propellants for DoD, NASA, or commercial space/hypersonic programs.
• Background in fast‑paced aerospace or defense production environments (startups or primes).
• Experience scaling processes from laboratory/prototype to low-rate or high-rate production.
• Familiarity with insensitive munitions practices, motor case interfaces, or propellant-to-liner bonding processes.
• Prior involvement in facility stand‑up, equipment commissioning, or production ramp of energetic materials lines.
• Experience with ITAR‑controlled programs and classified manufacturing environments.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

Benefits And Perks

• All full‑time employees are granted meaningful long‑term equity, sharing in the company's significant growth trajectory.
• We offer four (4) weeks of paid time off, ten (10) company‑paid holidays.
• Comprehensive health benefits - including 100% employee‑covered medical and strong dependent coverage, along with dental and vision plans.
• We also provide paid parental leave to support growing families, a $100 monthly fitness stipend to promote health and performance, and onsite EV charging for convenience.
• Employees enjoy perks like catered meals, company‑covered food during high‑demand periods and a fully stocked kitchen to stay fueled throughout the day.

Security Clearance

While this position does not currently require a U.S government‑issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S government‑issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance.

Affirmative Action/EEO Statement

Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.