Propellant Manufacturing Engineer - Hypersonics

Castelion Corporation

Torrance (CA)

On-site

USD 140,000 - 190,000

Full time

14 days+

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Benefits offered by this job

Equity

Paid time off

Medical coverage

Parental leave

Fitness stipend

EV charging

Job summary

Castelion Corporation seeks a Propellant Manufacturing Engineer to lead and execute propellant manufacturing for solid rocket motors supporting hypersonic programs. You will optimize formulation, mixing, casting, curing, and related processes, working hands-on with energetic materials in a high-consequence setting to improve safety, yield, and throughput.

You will collaborate with Propulsion Design, Quality, Automation & Controls, and Test teams to meet stringent requirements, with opportunities

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, 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 mixing, casting, curing, and finishing.
Develop and document process parameters, work instructions, and control plans.
Execute DFM and PFMEA activities; drive SPC and yield improvement.
Support NPI by translating propellant formulation and grain design requirements into scalable manufacturing processes.
Perform root-cause analysis and implement CAPA; collaborate on automation while maintaining safety.
Ensure compliance with energetic materials handling protocols and regulations.
Assist with equipment selection, qualification, maintenance, and validation.
Interface with suppliers to improve materials and processes.
Mentor junior engineers and support training and standardization.
Support facility ramp at Midland, TX and Project Ranger in New Mexico.