Propellant Manufacturing Engineer - Hypersonics Lead

Next Matter

Torrance (CA)

On-site

USD 120,000 - 180,000

Full time

14 days+

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Benefits offered by this job

Equity

Paid time off

Health benefits

Parental leave

Fitness stipend

EV charging

Catered meals

Job summary

Castelion in the United States is seeking a Propellant Manufacturing Engineer to lead SRM propellant production, including formulation, mixing, casting, curing, and process optimization for DoD-level hypersonic programs. You will work hands-on with energetic materials in a high-consequence environment, driving safety, yield, and throughput.

Collaborate with design, manufacturing, quality, and automation teams; contribute to NPI ramp, process validation, and documentation.

Qualifications

Bachelor’s or Master’s in Chemical/Materials/Manufacturing Engineering or related field.
5+ years in manufacturing/process engineering, with 3+ years in solid propellants or energetic materials.
Experience scaling propellant processes and batch operations in regulated environments.
Hands-on experience with propellant mixing, vacuum casting, and curing.
Strong knowledge of rheology, material interactions, and quality attributes.
Experience with PFMEA and SPC; proficiency in Minitab or similar tools.
Ability to read engineering drawings and 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 DFM and PFMEA activities; drive SPC and yield improvement initiatives.
Support 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 to improve mixing, casting, and handling automation while maintaining safety and process control.
Ensure compliance with energetic materials handling protocols, DoD 4145.26-M, ATF, ITAR, and site explosive safety standards.
Support equipment selection, qualification, maintenance, and process validation for mixers, casting systems, ovens, and tooling.
Interface with suppliers on propellant ingredients and materials; contribute to supplier process improvements.
Mentor junior engineers and technicians; contribute to training programs and standardization across production sites.
Support facility ramp and capability expansion at Midland, TX and Project Ranger campus in New Mexico.