Project Engineer

About Prometheus Energetics Prometheus Energetics is an independent U.S.-based merchant supplier of solid rocket motors and warheads. A joint venture between Kratos Defense & Security Solutions and Rafael Advanced Defense Systems, Prometheus combines U.S. industrial speed and credibility with decades of combat-proven designs, manufacturing know-how, and technical training to deliver field-ready products at scale.



 

Position Summary

Prometheus Energetics is seeking an experienced Project Engineer to lead a small team in setting up and operating a rapid prototyping and test facility in Bloomington, Indiana, dedicated to fabricating and testing single solid rocket motors (SRMs).

 

In this high-impact role, you will lead a nimble engineering team responsible for bringing a greenfield energetic lab, build facility, and test infrastructure online. You will bridge early-stage motor design and rapid shop-floor execution—overseeing everything from facility setup, specialized tooling, and equipment commissioning to energetic mixing, casting, motor assembly, and static test execution. Working closely with Engineering, Operations, Quality, EHS, and technology-transfer partners, you will ensure fast-turn prototype builds and static firings meet all technical, performance, and high-hazard safety requirements.

Key Responsibilities

Greenfield Facility Setup, Equipment & Test Integration

• Lead technical execution for the layout, tooling integration, and installation of energetic processing and test equipment (mixers, casting chambers, rotation carts, remote-handling systems, and static test stands) for single rocket motor builds.
• Establish, prove out, and sustain rapid-turn manufacturing processes, operational routers, tooling sheets, and detailed Standard Work Instructions (SWIs) for propellant handling, motor assembly, casting/curing, and static test prep.
• Define capital equipment and test instrumentation specifications, evaluate vendor proposals, and manage full-lifecycle acquisition, site acceptance testing (SAT), and equipment commissioning prior to active energetic processing and testing.

Team Leadership & Rapid Execution

• Directly lead a small, agile team of tooling, process, and test engineers through initial facility buildout, process qualification, and rapid motor fabrication/test cycles.
• Drive project schedules, milestone deliverables, technical risk management, and budget allocation for facility capital equipment, prototype tooling, and test instrumentation.
• Serve as the primary technical interface with prototype lab chemists, test technicians, and EHS teams to establish safe operational workflows, shop-floor troubleshooting guidelines, and rapid-iteration feedback loops between motor builds and test firings.

Non-Conformance, MRB & Process Validation

• Act as a voting member on the Material Review Board (MRB) to evaluate single-motor prototype non-conformances, perform engineering dispositions, and implement containment protocols.
• Lead formal Root Cause Corrective Action (RCCA) investigations for build anomalies, test deviations, process escapes, and tooling wear using 5-Why, Fishbone, and 8D methodologies.
• Apply Lean/Six Sigma practices, Process Failure Mode and Effects Analysis (PFMEA), and mistake-proofing (poka-yoke) controls early in the prototyping and testing phase to simplify future transition into high-rate production.

Explosive Safety, ESD & Regulatory Compliance

• Partner with Environmental Health & Safety (EHS) and Energetics Safety teams to strictly enforce site-specific explosive safety standards (DoD 4145.26-M), Electrostatic Discharge (ESD) controls, NFPA 495/652, and OSHA Process Safety Management (PSM) guidelines across build and test operations.
• Establish site classification standards, quantity-distance (Q-D) criteria, grounding/bonding requirements, and blast mitigation/suppression controls for rapid prototyping and static testing.
• Ensure full compliance with AS9100 quality standards, federal ammunition and explosives regulations, and trade compliance protocols (ITAR / EAR).

 

Performance Management

Establish actionable dashboards, review tooling performance with engineering and operational leadership, and hold owners accountable for recovery and improvement plans. Measures may include:

• Rapid prototype facility milestone execution, test stand commissioning schedules, and process design-to-release compliance.
• Lead time for single rocket motor prototype iteration, build-to-test cycle speed, and milestone delivery.
• Vendor quality, delivery performance, and technical drawing compliance for specialized prototyping equipment, tooling, and test instrumentation.
• First-pass yield, prototype scrap/rework impact, and early-stage cost of poor quality mitigation.
• Root-cause investigation aging, recurrence prevention, and RCCA effectiveness during pilot builds and test firings.
• Equipment proof-load, test stand calibration, and preventive maintenance plan compliance.
• Explosive safety, ESD, and ergonomic compliance across all active processing and test assets.
• Small team capability development, technical mentorship, and rapid-response project support effectiveness.

Required Qualifications

 

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Chemical Engineering, or a related technical discipline. Demonstrated work history may substitute for a degree.
• Minimum of 6+ years of progressive engineering experience in solid rocket propulsion, pyrotechnics, or hazardous energetic materials processing, including experience leading small technical teams or project workflows.
• Proficiency in 3D CAD software (e.g., PTC Creo, Siemens NX, SolidWorks) and Product Data Management (PDM/PLM) systems (e.g., Windchill).
• Solid understanding of Geometric Dimensioning and Tolerancing (GD&T per ASME Y14.5), structural strength of materials, and precision metal/composite fabrication methods.
• Proven experience generating assembly routers, process flow diagrams, PFMEAs, and detailed work instructions for complex solid rocket motor hardware.
• Deep knowledge of DoD energetics safety standards (DoD 4145.26-M), Process Safety Management (PSM), and hazardous location classifications (Class I/II, Div 1/2).
• Excellent written, verbal, analytical, and executive communication skills.
• U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

 

Preferred Qualifications

• Master of Science in Mechanical Engineering, Aerospace Engineering, Chemical Engineering, or Engineering Management.
• Minimum of 10+ years of progressive engineering experience in solid rocket propulsion, pyrotechnics, or hazardous energetic materials processing, including experience leading small technical teams or project workflows.
• Direct experience standing up rapid-prototyping, pilot manufacturing, or ground-testing facilities for solid rocket motors in a defense startup or expansion environment.
• Hands-on familiarity with energetic mixing/casting equipment, remote-operated tooling/robotics, static test stands, thrust-termination systems, and high-speed data acquisition (DAQ) equipment.
• Background in developing standard operating procedures (SOPs), hazard analyses (PHA/HAZOP), static test safety protocols, and Explosive Facility Safety Site Plans.
• ASQ certifications (CQE, CQA), formal GD&T certification, or Six Sigma Green/Black Belt credentials.
• Active U.S. Secret Security Clearance or higher.

 

Work Environment & Physical Requirements

• Work is performed in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas subject to enhanced safety and security controls.
• Must be able to wear required personal protective equipment (PPE) and comply with site safety, explosive-safety, electrostatic discharge (ESD), and access-control requirements.
• Ability to move throughout a manufacturing site, inspect physical tooling, participate in shop-floor audits, and occasionally lift up to 25 pounds.
• Regular, reliable attendance is required. Periodic travel to vendor machine shops, secondary company facilities, or customer sites may be required during startup, tool qualification, or critical production events.

 

Benefits

• Medical, dental, and vision insurance
• Life and AD&D insurance; short- and long-term disability coverage
• 401(k) savings plan
• Paid time off and company holidays