Propellant Manufacturing Engineer - Equity Eligible

Castelion; Torrance (CA); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Equity

Paid time off

Holidays

Health benefits

Parental leave

Fitness stipend

EV charging

Catered meals

Stocked kitchen

Job summary

Castelion is seeking a Propellant Manufacturing Engineer to lead solid rocket motor propellant processes for SRM production, collaborating with Design, Quality, Automation & Controls, and Test teams. You will develop robust manufacturing processes, optimize parameters, and drive safety and throughput as production scales from prototype to high-rate manufacture.

The role emphasizes DFM/DFMEA, SPC, NPI support, and hands-on work with energetic materials in a regulated environment, with a focus on

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.

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.

Skills

Chemical Engineering

Materials Science

Manufacturing Engineering

Propellant Knowledge

Process Engineering

Statistical Tools (Minitab)

PFMEA

Reading Engineering Drawings

Energetic Materials Safety

Data Collection & Analysis

Education

Bachelor’s or Master’s in Chemical Engineering or related field

Tools

Minitab

Job description

Castelion is seeking a Propellant Manufacturing Engineer to lead solid rocket motor propellant processes for SRM production, collaborating with Design, Quality, Automation & Controls, and Test teams. You will develop robust manufacturing processes, optimize parameters, and drive safety and throughput as production scales from prototype to high-rate manufacture.

The role emphasizes DFM/DFMEA, SPC, NPI support, and hands-on work with energetic materials in a regulated environment, with a focus on