Senior Propellant Formulation & Casting Engineer

Castelion; Torrance (CA); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Stock incentives

Medical, vision, and dental insurance

Four weeks paid time off

Job summary

Castelion in the United States is seeking a Senior Materials & Process Engineer to act as the technical authority for solid rocket motor propellant. You will develop, qualify, and scale propellant formulations and manufacturing processes to meet performance, production rate, and safety requirements.

The role requires hands-on experience with energetic materials, propellant characterization, and production-scale process development, with a focus on quality, safety, and compliance.

Qualifications

• BS in chemistry, chemical engineering, materials science/engineering or related discipline.
• 5+ years of experience with energetic materials, preferably in aerospace.
• Experience with propellant characterization techniques including mechanical testing, impact, static, burn-rate, and impulse testing.
• Excellent written and verbal communication skills.
• Must be authorized to work in the U.S. and comply with ITAR requirements.

Responsibilities

• Serve as SME for energetic materials and propellant processing, ensuring safety standards.
• Scale propellant mixing and casting from development to production with cross‑functional teams.
• Implement QA and qualification testing to ensure material consistency and performance.
• Develop and maintain material specifications, process controls, and test plans.
• Support root‑cause investigations and continuous improvement related to propellant performance and safety.

Skills

Energetic materials expertise

Mechanical testing

Impact testing

Static testing

Burn-rate testing

Impulse testing

Written and verbal communication

Education

Bachelor's degree in chemistry or related field

Master's degree in chemistry/chemical engineering/materials science

Job description

Castelion in the United States is seeking a Senior Materials & Process Engineer to act as the technical authority for solid rocket motor propellant. You will develop, qualify, and scale propellant formulations and manufacturing processes to meet performance, production rate, and safety requirements.

The role requires hands-on experience with energetic materials, propellant characterization, and production-scale process development, with a focus on quality, safety, and compliance.