Propellant Manufacturing Engineer: Scale to Production

Front Door Defense; Torrance (CA); On-site; USD 140,000 - 210,000; Full time

Benefits offered by this job

Equity participation

PTO 4 weeks + 10 holidays

Health benefits (medical/dental/vision

Parental leave

Fitness stipend

Onsite EV charging

Catered meals

Job summary

Castelion is seeking a Propellant Manufacturing Engineer to lead scaling of solid rocket motor propellant processes from pilot to high-rate production, ensuring safety, quality, and throughput. You will own mixing, casting, curing, and related operations while collaborating with multiple teams to meet stringent DoD/ITAR standards.

The role requires 5+ years in propellant or energetic materials with hands-on experience in regulated environments, PFMEA/SPC usage, and process documentation.

Qualifications

• Bachelor's or Master's in chemical/related engineering.
• 5+ years in manufacturing/process engineering with 3+ years hands-on propellant or energetic materials.
• Experience scaling mixing/casting/batch operations in regulated environments.
• Hands-on with propellant mixing, vacuum casting, and curing.
• Knowledge of propellant rheology and quality attributes.
• Proficiency with PFMEA, SPC, and process documentation.
• Data collection for batch processes and instrumentation.
• ITAR or energetic materials safety familiarity.

Responsibilities

• Own or lead propellant manufacturing processes across mixing, casting and curing.
• Develop and improve process parameters, work instructions and control plans.
• Run DFM/Process FMEA; drive SPC and yield improvements.
• Support NPI by translating requirements into scalable processes.
• Perform root-cause analysis and implement CAPAs.
• Collaborate with Automation & Controls to improve equipment and safety.
• Ensure compliance with energetic materials safety and regulations.
• Support equipment selection, qualification, maintenance and validation.
• Interface with suppliers for propellant ingredients and materials.
• Mentor junior engineers and contribute to training.
• Assist ramp at Midland, TX and Project Ranger NM sites.

Skills

Propellant manufacturing

Process scaling

Root-cause analysis

Regulated environment

Data analysis

Education

Bachelor's or Master's in Chemical/Materials/Manufacturing Engineering

Tools

Minitab

PFMEA

SPC

Batch data collection

Job description

Castelion is seeking a Propellant Manufacturing Engineer to lead scaling of solid rocket motor propellant processes from pilot to high-rate production, ensuring safety, quality, and throughput. You will own mixing, casting, curing, and related operations while collaborating with multiple teams to meet stringent DoD/ITAR standards.

The role requires 5+ years in propellant or energetic materials with hands-on experience in regulated environments, PFMEA/SPC usage, and process documentation.