Senior Manufacturing Engineer, Solid Rocket Motors Hardware

Front Door Defense; Torrance (CA); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

Employee Equity

Four weeks paid time off

Company paid holidays

100% medical coverage for employees

401(k) plan

Up to 10 weeks paid parental leave

Monthly fitness stipend

Job summary

Front Door Defense in Torrance, California is seeking a Senior Manufacturing Engineer to lead key manufacturing processes for solid rocket motors supporting advanced defense systems. This role is pivotal in developing, optimizing, and executing production processes while ensuring high quality and efficiency.

The ideal candidate will have over 5 years of manufacturing experience in aerospace, especially with solid rocket motors, and will collaborate closely with various engineering teams. Strong skills in CAD and process improvement methodologies are essential.

Qualifications

• 5+ years of manufacturing engineering experience, 3+ years with solid rocket motors.
• Demonstrated success in process development from prototype to production.
• Strong technical problem-solving and decision-making abilities.

Responsibilities

• Lead development and optimization of SRM manufacturing processes.
• Drive the implementation of Design for Manufacturability principles.
• Perform root-cause analysis for process issues.

Skills

Manufacturing engineering

Solid rocket motors

Process optimization

Propellant mixing

CAD (SolidWorks or NX)

Education

Bachelor’s degree in aerospace engineering or related field

Master’s degree in Manufacturing or related engineering

Tools

Statistical Process Control (SPC)

Robotics

Automation systems

Job description

Senior Manufacturing Engineer, Solid Rocket Motors

Location: Torrance, California, United States

About The Role

Castelion is moving quickly to develop and deliver advanced defense systems. The Senior Manufacturing Engineer will lead key manufacturing processes for solid rocket motors (SRM) supporting Castelion's hypersonic strike weapons, including the Blackbeard program. This role focuses on developing, optimizing, qualifying, and executing production processes for propellant mixing and casting, motor cases, liners/insulators, nozzles, and final motor integration.

You will drive process improvements, support the transition from prototype and research builds to scalable high‑rate production, and ensure high quality, safety, and efficiency. Working closely with Design, Propulsion, Automation & Controls, Quality, and Test teams, you will contribute to new product introduction, continuous improvement, and facility ramp‑up at our manufacturing sites.

Responsibilities

• Lead development and optimization of assigned SRM manufacturing processes, including propellant formulation/mixing, vacuum casting, filament winding, liner/insulator application, nozzle assembly, curing, and integration.
• Drive Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, control plans, and statistical process control (SPC) to improve yield, reduce cycle time, and lower cost.
• Support new product introduction (NPI) and design change implementation by providing manufacturing input and executing process qualifications.
• Perform root‑cause analysis and lead corrective/preventive actions for process issues and defects.
• Integrate NDE methods (ultrasonic, CT, shearography, thermography) and in‑process inspection into production workflows.
• Collaborate with Automation & Controls to implement robotics, vision systems, and digital tools (MES, data analytics) for improved efficiency and traceability.
• Author and maintain work instructions, process documentation, and training materials; mentor junior manufacturing engineers.
• Ensure compliance with energetic materials handling, DoD 4145.26‑M, ATF regulations, ITAR, and explosive safety standards.
• Support equipment qualification, process validation, and production ramp at the Midland, TX facility and the Project Ranger campus in New Mexico.
• Interface with suppliers on materials, tooling, and equipment to resolve issues and improve incoming quality.

Basic Qualifications

• Bachelor’s or advanced degree in aerospace engineering, manufacturing engineering, materials engineering, mechanical engineering or physics.
• 5+ years of manufacturing engineering experience, including at least 3+ years hands‑on work with solid rocket motors, energetic materials processing, or complex assembly in aerospace or defense.

Preferred Experience

• Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Materials Science, or related field.
• 6–10+ years of manufacturing engineering experience, including at least 3+ years hands‑on work with solid rocket motors, energetic materials processing, or complex assembly in aerospace or defense.
• Demonstrated success developing and scaling manufacturing processes from prototype to low‑rate or full‑rate production.
• Strong hands‑on experience with propellant mixing/casting, composite filament winding or layup, liner/insulator processing, and propulsion hardware assembly.
• Proficiency in CAD (SolidWorks or NX), GD&T, tooling/fixture design, and process documentation.
• Familiarity with industrial automation, PLCs, robotics, or MES systems is a plus.
• Working knowledge of energetic materials safety and hazardous process manufacturing.
• Experience in fast‑paced environments such as aerospace startups.
• Background supporting high‑rate composite manufacturing, insensitive munitions practices, or vertical integration of propulsion hardware.
• Prior involvement in facility stand‑up, equipment qualification, or production ramp activities.
• Familiarity with ITAR‑controlled programs and classified manufacturing.
• Strong technical problem‑solving and data‑driven decision‑making abilities.
• Excellent collaboration and communication skills across engineering, production, and quality teams.
• Ability to mentor junior engineers and contribute to process standardization.
• Safety‑first mindset with attention to detail in high‑consequence energetic environments.
• Proactive, hands‑on approach with the ability to manage multiple priorities in a fast‑paced setting.

Benefits And Perks

• Employee Equity – meaningful equity for all full‑time employees.
• Personal Time Off – four (4) weeks of paid time off.
• Company Paid Holidays – ten (10) paid holidays.
• Medical – plans 100% employee covered and 80% of dependent coverage.
• Dental & Vision – 90% coverage for employees, 80% for dependents.
• FSA/HSA – options that allow pre‑tax dollar allocation for medical and dependent care.
• Retirement – 401(k) plan offered.
• Paid Parental Leave – up to 10 weeks for birthing parents, up to 4 weeks for non‑birthing parents; additional paid pregnancy leave for CA employees.
• Meals & Catering – frequently catered lunches and team meals; company‑covered meals when required.
• Snacks & Beverages – fully stocked kitchen with unlimited snacks and drinks.
• Performance & Fitness – $100 monthly fitness stipend.
• EV Charging – onsite electric vehicle charging available.

Physical Demands

• Willingness to work extended hours and/or weekends as needed.
• Ability to travel up to 30% of the time.
• Ability to lift more than 50 lbs.

ITAR Requirements

Applicants must be a U.S. citizen or national, lawful permanent resident, refugee under 8 U.S.C. § 1157, or asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. This position may require access to classified information or restricted U.S. Government sites, systems, or information, depending on the company and applicable U.S. Government requirements.

Affirmative Action/EEO Statement

Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced by protected status.