Propellant Manufacturing Engineer - High-Impact Propulsion

Castelion Corporation; Midland (TX); On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

Equity in company

4 weeks PTO

10 company-paid holidays

Health benefits (medical) and dental/视

Parental leave

$100 monthly fitness stipend

Onsite EV charging

Job summary

Castelion Corporation in Midland, TX seeks a Propellant Manufacturing Engineer to lead and execute propellant production for solid rocket motors, advancing from prototype to high-rate production. You will own mixing, casting, curing, and process validation in a high-consequence environment with strict safety and regulatory requirements.

Responsibilities include developing robust procedures, driving DFM and SPC, supporting NPI, and mentoring junior engineers while ensuring compliance with DoD and

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

Propellant manufacturing

Batch processing

SPC

Process FMEA

DFM

Energetic materials safety

Education

Bachelor's or Master's in Chemical/Materials/Mechanical Eng

Tools

Minitab

Job description

Castelion Corporation in Midland, TX seeks a Propellant Manufacturing Engineer to lead and execute propellant production for solid rocket motors, advancing from prototype to high-rate production. You will own mixing, casting, curing, and process validation in a high-consequence environment with strict safety and regulatory requirements.

Responsibilities include developing robust procedures, driving DFM and SPC, supporting NPI, and mentoring junior engineers while ensuring compliance with DoD and