Propulsion Engineer III

Karman Space & Defense; Mukilteo (WA); On-site; USD 120,000 - 155,000; Full time

Benefits offered by this job

Health insurance

401k with match

Paid time off

Health savings account

Flexible spending accounts

Life insurance

Short-term disability

Long-term disability

Job summary

Karman Space & Defense, a leader in rapid design and production of space and defense systems, seeks an experienced propulsion engineer in Mukilteo, WA. You will lead solid rocket motor propulsion development, drive system-level ballistic modeling, and collaborate across engineering teams to deliver mission-ready propulsion solutions.

The role requires strong internal ballistic modeling skills, a DoD Secret clearance or ability to obtain one, and 4–10 years of aerospace/defense experience.

Qualifications

• Bachelor's degree in mechanical engineering, aerospace engineering, physics, or related field or equivalent experience.
• 4–10 years aerospace/defense engineering experience.
• Strong understanding of propulsion systems and internal ballistics modeling.
• Proven experience developing propulsion internal ballistic models, preferably for solid rocket motors.
• Knowledge of military and commercial design specifications.
• A DoD Secret clearance or ability to obtain one.

Responsibilities

• Lead solid rocket propulsion design across grain geometry, case design, insulation, inhibitors, igniters, and nozzles.
• Conceptualize, design, and develop propulsion devices and systems per requirements.
• Perform full ballistic modeling: propellant sizing, nozzle sizing, insulation, inhibitors, performance analysis.
• Support thermal, ablation, and erosion analyses when applicable.
• Create 2D layouts and 3D models to define propulsion concepts.
• Verify calculations and models; mentor junior engineers.
• Document performance requirements, test plans, and compliance evidence.
• Review propulsion designs for cost, manufacturability, and quality.
• Create engineering drawings, BOMs, and manufacturing specs.
• Support manufacturing, QA, testing, and deployment throughout lifecycle.
• Provide technical support to internal teams and customers.
• Assist bench and field testing, including static fire setup and instrumentation.
• Evaluate test data: acoustic stability, impulse, pressure, and thrust.
• Mentor and guide propulsion system development.

Skills

Solid rocket propulsion

Internal ballistic modeling

Propulsion systems

Team mentorship

Education

Bachelor's degree in mechanical/aerospace/physics

Master's degree (preferred)

Tools

CAD/CAE tools

ASME Y14.5 / GD&T

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Full Time Professional Mukilteo, WA, US

2 days ago Requisition ID: 4035

Salary Range: $120,000.00 To $155,000.00 Annually

Karman Space & Defense is a leader in the rapid design, development, and production of critical, next-generation system solutions that align with the U.S. Department of War and its allies’ core mission priorities, and meet the accelerating demand for access to space. Building on nearly 50 years of success, we deliver Payload & Protection Systems, Aero/Hydrodynamic Interstage Systems, and Propulsion & Launch Systems to more than 80 prime contractors supporting over 130 space and defense programs.

This role is part of our Tactical Missiles and Integrated Defense Systems business, which designs and develops integrated missile and defense systems that support critical missions across air, land, and sea. We combine comprehensive analysis, engineering, and program execution capabilities to deliver mission-tailored solutions that reduce lead times, lower costs, and simplify complex multi-vendor supply chains. Backed by decades of flight‑proven and fielded performance, we design and build mission‑critical technologies including launch systems, propulsion, payload integration solutions, UAV components, missile subsystems, and Safe & Arm systems.

In this role, you will lead solid rocket motor propulsion development, driving system‑level ballistic modeling, component design, and test evaluation for advanced aerospace and defense programs. You will develop conceptual and detailed designs, verify analyses, support manufacturing and static fire testing, and collaborate across engineering teams to deliver mission‑ready propulsion solutions that meet stringent performance and reliability requirements.

Responsibilities

• Supports solid rocket propulsion system design across grain geometry, case design, insulation, inhibitors, igniters, and nozzles.
• Conceptualizes, designs, and develops propulsion devices and systems based on customer requirements and engineering standards.
• Performs full ballistic modeling, including propellant selection, propellant sizing, nozzle sizing, insulation and inhibitor definition, and overall performance analysis.
• Performs or supports thermal, ablation, and erosion analyses when applicable.
• Creates 2‑D layouts and 3‑D solid models to define propulsion concepts and configurations.
• Verifies calculations, ballistic models, and analysis work completed by peers and junior engineers.
• Documents performance requirements, test plans, test procedures, test reports, and compliance evidence.
• Reviews propulsion designs for cost, manufacturability, and quality considerations.
• Creates engineering drawings, bills of materials, manufacturing requirements, and inspection specifications.
• Supports manufacturing, assembly, quality assurance, testing, and deployment throughout the propulsion development lifecycle.
• Provides technical support to internal teams, external customers, and business development activities.
• Supports bench and field testing, including static fire test setup and instrumentation selection.
• Evaluates static fire test data, including acoustic stability, delivered impulse, pressure, and thrust behavior.
• Mentors junior engineers and provides technical guidance in propulsion system development.

Required Qualifications

• Bachelor’s degree in mechanical engineering, aerospace engineering, physics, or a related field; or equivalent relevant experience.
• Typically 4–10 years of aerospace or defense engineering experience.
• Strong understanding of propulsion systems and internal ballistics modeling.
• Proven experience developing propulsion internal ballistic models, preferably for solid rocket motors.
• Knowledge of military and commercial design specifications.
• A current U.S. Department of Defense (DoD) Secret security clearance or the ability to obtain and maintain one.

Preferred Qualifications

• Master’s degree or advanced degree in mechanical engineering, aerospace engineering, physics, or a related field.
• Experience with thermal, ablation, or erosion analysis.
• Experience with acoustic stability analysis.
• Experience with igniter sizing.
• Knowledge of CAD/CAE tools relevant to mechanical systems design.
• Familiarity with ASME Y14.5 and Geometric Dimensioning and Tolerancing (GD\&T).
• Casting tooling experience.
• Medical, dental, and vision insurance
• 401(k) with company match
• Paid time off
• Health Savings Account (HSA) with company contribution
• Flexible Spending Accounts (FSA)
• Company‑paid life and AD\&D insurance
• Short‑and long‑term disability coverage

Karman Space and Defense is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, age, disability, genetic information, protected veteran status, or any other status protected by applicable law.