Senior Propulsion Engineer, Rocket Motor Soft Goods Lead

Castelion; Torrance (CA); On-site; USD 140,000 - 190,000; Full time

Job summary

Castelion seeks a Senior Propulsion Engineer to design and deliver rocket motor soft goods, for long-range hypersonic strike vehicles. You will lead architecture, perform thermal, chemical, and structural analyses, and ensure robust bonding and integration with propellant and motor cases.

You will mentor junior engineers and collaborate with propulsion, structures, and manufacturing teams in a fast-paced hardware-driven environment, with strong emphasis on test campaigns and failure

Qualifications

• Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field.
• 5+ years of experience in rocket propulsion or high-temperature material systems, with focus on soft goods or internal motor components.
• Strong background in insulation materials, liners, and bonding systems used in solid rocket motors.
• Experience with material processing techniques for elastomers, ablatives, or composite insulation systems.
• Proficiency in analysis and modeling tools (e.g., MATLAB, ANSYS, or equivalent).

Responsibilities

• Design and develop rocket motor soft goods, including liners, insulators, inhibitors, and internal thermal protection systems.
• Lead the architecture and detailed design of soft goods systems to ensure compatibility with propellant, case materials, and motor operating conditions.
• Perform thermal, chemical, and structural analyses to ensure performance and durability under high-temperature, high-pressure environments.
• Develop and optimize material selections and formulations in collaboration with materials and manufacturing teams.
• Define and manage bonding strategies between propellant, liner, insulation, and motor case to ensure robust adhesion and prevent debonding.
• Work closely with propulsion, structures, and manufacturing teams to ensure seamless integration of soft goods with overall motor design.
• Support material processing, fabrication, and quality control of soft goods components.
• Plan and execute test campaigns, including subscale and full-scale motor testing, and analyze results to drive design improvements.
• Conduct failure analysis and root cause investigations related to insulation performance, erosion, cracking, or debonding.
• Mentor junior engineers and contribute to best practices in soft goods design and processing.
• Partner closely with program leadership to make technical trades aligned with mission success.

Skills

Rocket propulsion

High-temperature materials

Thermal analysis

Materials processing

Problem solving

Leadership

Education

Aerospace/Mechanical/Materials Degree

Tools

MATLAB

ANSYS

Job description

Castelion seeks a Senior Propulsion Engineer to design and deliver rocket motor soft goods, for long-range hypersonic strike vehicles. You will lead architecture, perform thermal, chemical, and structural analyses, and ensure robust bonding and integration with propellant and motor cases.

You will mentor junior engineers and collaborate with propulsion, structures, and manufacturing teams in a fast-paced hardware-driven environment, with strong emphasis on test campaigns and failure