Senior Rocket Propulsion Engineer – Motors & Testing

Castelion; Rio Rancho (NM); On-site; USD 150,000 - 190,000; Full time

Benefits offered by this job

Benefits package

Job summary

Castelion is seeking a Senior Propulsion Engineer to design, build, and test rocket motor systems for its long-range hypersonic strike vehicles. You will lead propulsion hardware architecture, perform internal ballistics analyses, and coordinate with multidisciplinary teams to ensure system reliability and mission success.

The role involves planning static fires, propellant processing, and hardware integration, with opportunities to mentor junior engineers and influence design decisions in a

Qualifications

• 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).

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

Internal ballistics

Thermal/structural analyses

Laboratory testing

Problem solving

Education

Bachelors/Masters/PhD in Aerospace or Mechanical Engineering

Tools

MATLAB

ANSYS

Job description

Castelion is seeking a Senior Propulsion Engineer to design, build, and test rocket motor systems for its long-range hypersonic strike vehicles. You will lead propulsion hardware architecture, perform internal ballistics analyses, and coordinate with multidisciplinary teams to ensure system reliability and mission success.

The role involves planning static fires, propellant processing, and hardware integration, with opportunities to mentor junior engineers and influence design decisions in a