Propellant Manufacturing Engineer III+

Karman Space & Defense; Mukilteo (WA); On-site; USD 110,000 - 165,000; Full time

Job summary

An established industry player seeks a skilled Propellant Manufacturing Engineer to join their dynamic team in Mukilteo. This role involves hands-on processing of energetic materials, focusing on casting and curing propellant into motor cases. The ideal candidate will have extensive experience in propellant formulation and manufacturing processes, ensuring safety and quality in handling energetic materials. You will work closely with design and test teams to enhance propellant performance and support motor development. This position offers an exciting opportunity to contribute to mission-critical systems in aerospace and defense, pushing the boundaries of innovation in a collaborative environment.

Qualifications

• 5+ years of experience in propellant processing or related fields.
• Hands-on experience with casting, curing, and motor integration.

Responsibilities

• Oversee propellant mixing, casting, and curing processes.
• Analyze test data to validate propellant characteristics.
• Collaborate with cross-functional teams for optimization.

Skills

Propellant Processing

Manufacturing Processes

Energetic Materials Handling

Problem-Solving Skills

Attention to Detail

Education

B.S. or M.S. Degree in Aerospace Engineering

B.S. or M.S. Degree in Chemical Engineering

B.S. or M.S. Degree in Mechanical Engineering

Tools

Non-Destructive Testing (NDT)

Statistical Process Control (SPC)

Job description

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Propellant Manufacturing Engineer III+

Technical Mukilteo, WA, US

3 days ago Requisition ID: 2663

Salary Range: $110,000.00 To $165,000.00 Annually

SUMMARY:

We are seeking a highly skilled Propellant Manufacturing Engineer to join our team. This role will focus on the hands-on processing of energetic materials, specifically casting and curing propellant into cases and integrating them into final motor packages. The ideal candidate will have exposure to propellant formulation, experience in manufacturing processes, and handling energetic materials safely. Expertise in test analysis (propellant ballistics) and motor design is a significant plus.

ABOUT US:

Karman Space & Defense provides concept-to-production solutions for mission-critical systems on spacecraft, launch vehicles, missiles, hypersonics, and integrated defense systems. We believe that solving the industry’s most complex and mission-critical challenges requires relentless determination and a willingness to push the boundaries of possibility. Karman Space & Defense brings to bear unparalleled production capabilities, unmatched engineering expertise, and unflinching analysis to render the impossible, possible.

WHAT YOU WILL DO:

• Oversee and execute propellant mixing, casting, and curing processes.
• Ensure precision in loading and integration of propellant into motor cases.
• Work closely with design and test teams to optimize propellant performance and integration.
• Support motor development, qualification, and production efforts.
• Analyze test data and ballistic performance to validate propellant characteristics.
• Develop and improve manufacturing processes, tooling, and automation for efficiency and safety.
• Implement and oversee inspection and process control methods, ensuring consistency and adherence to specifications.
• Utilize non-destructive testing (NDT), dimensional inspections, and chemical analysis to verify propellant quality.
• Ensure compliance with safety regulations, quality standards, and industry best practices.
• Troubleshoot processing issues, defects, and performance anomalies.
• Collaborate with cross-functional teams including materials engineers, designers, and test engineers.

WHAT WE ARE LOOKING FOR:

• B.S. or M.S. Degree in Aerospace Engineering, Chemical Engineering, Mechanical Engineering or equivalent.
• Typically possesses 5+ years in propellant processing, manufacturing, or related energetic materials fields.
• Hands-on experience with casting, curing, and motor integration.
• Strong understanding of energetic materials handling, safety procedures, and quality control.
• Experience with inspection techniques, process validation, and statistical process control (SPC) in propellant manufacturing.
• Knowledge of propellant chemistry, performance modeling, and testing.
• Familiarity with instrumentation, test setups, and data acquisition for propulsion testing.
• Strong problem-solving skills, attention to detail, and ability to work in a fast-paced environment.
• Must be a U.S. citizen and able to obtain a DoD SECRET clearance.

Equal Opportunity Employer:

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities. The contractor will not discharge or in any other manner discriminate against employees or applicants because they have inquired about, discussed, or disclosed their own pay or the pay of another employee or applicant. However, employees who have access to the compensation information of other employees or applicants as a part of their essential job functions cannot disclose the pay of other employees or applicants to individuals who do not otherwise have access to compensation information, unless the disclosure is (a) in response to a formal complaint or charge, (b) in furtherance of an investigation, proceeding, hearing, or action, including an investigation conducted by the employer, or (c) consistent with the contractor’s legal duty to furnish information.

Karman is committed to equal employment opportunity. We will not discriminate against employees or applicants for employment on any legally recognized basis (“protected class”) including, but not limited to race; color; religion; genetic information; national origin; sex; pregnancy, childbirth, or related medical conditions; age; disability; citizenship status; uniform servicemember status; or any other protected class under federal, state, or local law. Our management is dedicated to ensuring the fulfillment of this policy with respect to hiring, placement, promotion, transfer, demotion, layoff, termination, recruitment advertising, pay, and other forms of compensation, training, and general treatment during employment.