Senior Rocket Propulsion Engineer - High-Performance Motors

Castelion Corporation; Torrance (CA); On-site; USD 150,000 - 190,000; Full time

Job summary

Castelion is seeking a Senior Propulsion Engineer to design, build, and test rocket motor systems for long-range hypersonic strike vehicles. You will work hands-on with multidisciplinary teams to develop solid motors and hardware from concept through flight test in a fast-paced, hardware-driven environment.

You will lead propulsion hardware architecture, perform internal ballistics and thermal analyses, and collaborate with structures, GNC, and manufacturing to ensure seamless integration and

Qualifications

• Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, or related field.
• 5+ years of experience in rocket propulsion design, analysis, and testing for aerospace or defense applications.
• Strong background in solid rocket motor design, including internal ballistics, grain design, and nozzle performance.
• Experience with propulsion testing, including static fire test setup, instrumentation, and data analysis.
• Familiarity with structural and thermal design considerations for high-temperature, high-pressure systems.
• Proficiency in analysis and modeling tools (e.g., MATLAB, ANSYS, or equivalent).
• Experience with hardware build, integration, and troubleshooting in a lab or test environment.

Responsibilities

• Design and develop rocket motor systems, including grain geometry, case structures, insulation, and nozzle assemblies
• Lead the architecture and detailed design of propulsion hardware to meet performance, structural, and thermal requirements
• Perform internal ballistics, thermal, and structural analyses to ensure motor performance and reliability under extreme operating conditions
• Work closely with structures, thermal, GNC, and manufacturing teams to ensure seamless integration of propulsion systems with the vehicle
• Support propellant selection, processing, and characterization in collaboration with materials and manufacturing teams
• Plan and execute static fire tests and development test campaigns, including instrumentation, data collection, and post-test analysis
• Conduct failure analysis and root cause investigations, driving design improvements and risk reduction
• Define and execute qualification and flight test plans, translating results into system-level improvements
• Optimize designs for performance, mass, manufacturability, and operational reliability
• Mentor junior engineers and contribute to best practices in propulsion system design and testing
• Partner closely with program leadership to make technical trades aligned with mission success

Skills

Rocket propulsion design

MATLAB/ANSYS

Data analysis

Hardware troubleshooting

Education

Aerospace/Mechanical Engineering degree

Tools

Instrumentation setup

Data acquisition systems

Job description

Castelion is seeking a Senior Propulsion Engineer to design, build, and test rocket motor systems for long-range hypersonic strike vehicles. You will work hands-on with multidisciplinary teams to develop solid motors and hardware from concept through flight test in a fast-paced, hardware-driven environment.

You will lead propulsion hardware architecture, perform internal ballistics and thermal analyses, and collaborate with structures, GNC, and manufacturing to ensure seamless integration and