Senior Rocket Propulsion Systems Engineer

Castelion Corporation; Torrance (CA); On-site; USD 180,000 - 260,000; Full time

Job summary

Castelion Corporation in Torrance, CA is seeking a Senior Propulsion Engineer to design and deliver rocket motor soft goods for long-range hypersonic strike vehicles. You will work hands-on with multidisciplinary teams to ensure reliability of liners, insulators, inhibitors, and internal thermal protection systems.

The role requires a strong background in high-temperature materials, bonding, and propulsion testing, plus mentorship of junior engineers.

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 thermal protection materials and behavior under high heat flux and pressure environments.
• Familiarity with propellant compatibility, adhesion, and chemical interactions with soft goods materials.
• Experience with material processing techniques for elastomers, ablatives, or composite insulation systems.
• Proficiency in analysis and modeling tools (e.g., MATLAB, ANSYS, or equivalent).
• Experience with propulsion testing, data analysis, and failure investigation.

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

Propulsion analysis

High-temperature materials

Material bonding systems

Failure analysis

Thermal protection systems

Mathematical modeling

Data interpretation

Education

Bachelor’s/Master’s/PhD in Aerospace, Mechanical or Materials Science

Tools

MATLAB

ANSYS

Job description

Castelion Corporation in Torrance, CA is seeking a Senior Propulsion Engineer to design and deliver rocket motor soft goods for long-range hypersonic strike vehicles. You will work hands-on with multidisciplinary teams to ensure reliability of liners, insulators, inhibitors, and internal thermal protection systems.

The role requires a strong background in high-temperature materials, bonding, and propulsion testing, plus mentorship of junior engineers.