Propellant Manufacturing Engineer: Scale-Up & Production

Front Door Defense; Rio Rancho (NM); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Equity

PTO 4 weeks

Holidays 10

Health benefits

Parental leave

Fitness stipend

EV charging

Catered meals

Job summary

Castelion seeks a Propellant Manufacturing Engineer to lead and scale solid rocket propellant production from prototype to high-rate manufacturing. You will develop, optimize, and qualify propellant formulation, mixing, casting, curing, and related processes in a safety-conscious environment, partnering with Design, Quality, and Automation teams.

Based in Rio Rancho, NM, you will mentor junior engineers, support NPI, and help expand capability at Midland, TX and New Mexico sites while ensuring

Qualifications

• 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.

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

Statistical analysis

Process optimization

Root cause analysis

Documentation

Team collaboration

Education

Bachelor's or Master's degree in Chemical Engineering, Materials Science, Manufacturing Engineering, Mechanical Engineering, or related technical field

Tools

Minitab

Process FMEA

Job description

Castelion seeks a Propellant Manufacturing Engineer to lead and scale solid rocket propellant production from prototype to high-rate manufacturing. You will develop, optimize, and qualify propellant formulation, mixing, casting, curing, and related processes in a safety-conscious environment, partnering with Design, Quality, and Automation teams.

Based in Rio Rancho, NM, you will mentor junior engineers, support NPI, and help expand capability at Midland, TX and New Mexico sites while ensuring