Propellant Manufacturing Engineer

Castelion Corporation; Rio Rancho (NM); On-site; USD 110,000 - 170,000; Full time

Job summary

Castelion is seeking a Propellant Manufacturing Engineer to lead and scale solid rocket motor propellant processes, supporting hypersonic programs with a focus on formulation, mixing, casting, curing, and related operations. You will work hands-on with energetic materials in a high-consequence environment to drive safety, reliability, and throughput as production ramps.

Responsibilities include developing process parameters, control plans, and documentation; executing DFMEA and SPC; supporting

Qualifications

• 5+ years manufacturing/process engineering experience.
• Hands-on work with solid propellants/energetic materials.
• Experience scaling mixing, casting, or batch operations in regulated environment.
• Experience with planetary/vertical mixers, vacuum casting, curing processes.
• Understanding propellant rheology, ingredient interactions, and quality attributes.
• Familiarity with process documentation, statistical tools, and root-cause methodologies.
• Ability to interpret engineering drawings and material data sheets.

Responsibilities

• Own or lead propellant manufacturing processes (ingredients, mixing, casting, curing).
• Develop, document, and improve process parameters and control plans.
• Execute DFM and PFMEA; drive SPC and yield improvement.
• Support NPI by translating requirements into scalable processes.
• Perform root-cause analysis and corrective actions; collaborate with Automation & Controls teams.

Skills

Propellant manufacturing

Batch processing

Statistical methods

Process documentation

Safety compliance

Education

Bachelor’s or Master’s degree in Chemical/Materials/Manufacturing Engineering

Tools

Minitab

PFMEA

Job description

Castelion is seeking a Propellant Manufacturing Engineer to lead and scale solid rocket motor propellant processes, supporting hypersonic programs with a focus on formulation, mixing, casting, curing, and related operations. You will work hands-on with energetic materials in a high-consequence environment to drive safety, reliability, and throughput as production ramps.

Responsibilities include developing process parameters, control plans, and documentation; executing DFMEA and SPC; supporting