Senior Structures & Composites Engineer, Rocket Motor Cases

Castelion Corporation; Rio Rancho (NM); On-site; USD 120,000 - 180,000; Full time

Job summary

Castelion Corporation in Rio Rancho, NM is seeking a Senior Structures & Composites Engineer to design and deliver rocket motor case structures for advanced defense systems. You will lead architectural and detailed design of COPVs and filament-wound cases, performing complex structural analysis and collaborating across propulsion, materials, and test teams.

The role requires 5+ years in aerospace structures, expertise with composites, and proficiency in industry-standard analysis tools.

Qualifications

• Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, or related field.
• 5+ years of experience in structural and composite design for aerospace or high-pressure pressure vessel applications.
• Strong background in composite materials, including filament winding, laminate theory, and failure criteria (e.g., Tsai-Wu, Hashin).
• Experience designing pressure vessels, COPVs, or rocket motor cases for high-pressure applications.
• Proficiency in structural analysis tools (e.g., ANSYS, Abaqus, NASTRAN, or equivalent).
• Familiarity with manufacturing processes for composites, including winding, curing, and inspection methods (e.g., NDI/NDT).
• Experience with proof/burst testing and structural validation of pressure vessels.

Responsibilities

• Design and develop rocket motor case structures, including COPVs and filament-wound composite cases.
• Lead the architecture and detailed design of motor cases, including load paths, interfaces, domes, bosses, and attachment features.
• Perform structural analysis of pressure vessels under internal pressure, thermal loads, and dynamic environments to ensure performance and reliability.
• Develop and analyze composite layups, fiber orientations, and manufacturing approaches to optimize strength, stiffness, and mass.
• Work closely with propulsion, materials, manufacturing, and test teams to ensure seamless integration of motor cases with propulsion systems.
• Support material selection, processing, and characterization for composite and high-temperature materials.
• Conduct failure analysis and root cause investigations, driving design improvements and risk reduction.
• Define and execute qualification and environmental test plans, including pressure testing, proof/burst testing, and vibration testing.
• Support prototyping, fabrication, and hardware bring-up, including troubleshooting manufacturing and structural performance issues.
• Optimize designs for mass efficiency, manufacturability, and operational reliability.
• Mentor junior engineers and contribute to best practices in composite and pressure vessel design.
• Partner closely with program leadership to make technical trades aligned with mission success.

Skills

Composite materials

Filament winding

Laminate theory

Failure criteria (Tsai-Wu, Hashin)

Structural problem solving

Education

Bachelors, Masters, or PhD in Aerospace or Mechanical Engineering

Tools

ANSYS

Abaqus

NASTRAN

Job description

Castelion Corporation in Rio Rancho, NM is seeking a Senior Structures & Composites Engineer to design and deliver rocket motor case structures for advanced defense systems. You will lead architectural and detailed design of COPVs and filament-wound cases, performing complex structural analysis and collaborating across propulsion, materials, and test teams.

The role requires 5+ years in aerospace structures, expertise with composites, and proficiency in industry-standard analysis tools.