Senior Manufacturing Engineer, Solid Rocket Motors Hardware

Senior Manufacturing Engineer, Solid Rocket Motors Location: Torrance, California, United States About The Role Castelion is moving quickly to develop and deliver advanced defense systems. The Senior Manufacturing Engineer will lead key manufacturing processes for solid rocket motors (SRM) supporting Castelion's hypersonic strike weapons, including the Blackbeard program. This role focuses on developing, optimizing, qualifying, and executing production processes for propellant mixing and casting, motor cases, liners/insulators, nozzles, and final motor integration. You will drive process improvements, support the transition from prototype and research builds to scalable high‑rate production, and ensure high quality, safety, and efficiency. Working closely with Design, Propulsion, Automation & Controls, Quality, and Test teams, you will contribute to new product introduction, continuous improvement, and facility ramp‑up at our manufacturing sites. Responsibilities Lead development and optimization of assigned SRM manufacturing processes, including propellant formulation/mixing, vacuum casting, filament winding, liner/insulator application, nozzle assembly, curing, and integration. Drive Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, control plans, and statistical process control (SPC) to improve yield, reduce cycle time, and lower cost. Support new product introduction (NPI) and design change implementation by providing manufacturing input and executing process qualifications. Perform root‑cause analysis and lead corrective/preventive actions for process issues and defects. Integrate NDE methods (ultrasonic, CT, shearography, thermography) and in‑process inspection into production workflows. Collaborate with Automation & Controls to implement robotics, vision systems, and digital tools (MES, data analytics) for improved efficiency and traceability. Author and maintain work instructions, process documentation, and training materials; mentor junior manufacturing engineers. Ensure compliance with energetic materials handling, DoD 4145.26‑M, ATF regulations, ITAR, and explosive safety standards. Support equipment qualification, process validation, and production ramp at the Midland, TX facility and the Project Ranger campus in New Mexico. Interface with suppliers on materials, tooling, and equipment to resolve issues and improve incoming quality. Basic Qualifications Bachelor’s or advanced degree in aerospace engineering, manufacturing engineering, materials engineering, mechanical engineering or physics. 5+ years of manufacturing engineering experience, including at least 3+ years hands‑on work with solid rocket motors, energetic materials processing, or complex assembly in aerospace or defense. Preferred Experience Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Materials Science, or related field. 6–10+ years of manufacturing engineering experience, including at least 3+ years hands‑on work with solid rocket motors, energetic materials processing, or complex assembly in aerospace or defense. Demonstrated success developing and scaling manufacturing processes from prototype to low‑rate or full‑rate production. Strong hands‑on experience with propellant mixing/casting, composite filament winding or layup, liner/insulator processing, and propulsion hardware assembly. Proficiency in CAD (SolidWorks or NX), GD&T, tooling/fixture design, and process documentation. Familiarity with industrial automation, PLCs, robotics, or MES systems is a plus. Working knowledge of energetic materials safety and hazardous process manufacturing. Experience in fast‑paced environments such as aerospace startups. Background supporting high‑rate composite manufacturing, insensitive munitions practices, or vertical integration of propulsion hardware. Prior involvement in facility stand‑up, equipment qualification, or production ramp activities. Familiarity with ITAR‑controlled programs and classified manufacturing. Strong technical problem‑solving and data‑driven decision‑making abilities. Excellent collaboration and communication skills across engineering, production, and quality teams. Ability to mentor junior engineers and contribute to process standardization. Safety‑first mindset with attention to detail in high‑consequence energetic environments. Proactive, hands‑on approach with the ability to manage multiple priorities in a fast‑paced setting. Benefits And Perks Employee Equity – meaningful equity for all full‑time employees. Personal Time Off – four (4) weeks of paid time off. Company Paid Holidays – ten (10) paid holidays. Medical – plans 100% employee covered and 80% of dependent coverage. Dental & Vision – 90% coverage for employees, 80% for dependents. FSA/HSA – options that allow pre‑tax dollar allocation for medical and dependent care. Retirement – 401(k) plan offered. Paid Parental Leave – up to 10 weeks for birthing parents, up to 4 weeks for non‑birthing parents; additional paid pregnancy leave for CA employees. Meals & Catering – frequently catered lunches and team meals; company‑covered meals when required. Snacks & Beverages – fully stocked kitchen with unlimited snacks and drinks. Performance & Fitness – $100 monthly fitness stipend. EV Charging – onsite electric vehicle charging available. Physical Demands Willingness to work extended hours and/or weekends as needed. Ability to travel up to 30% of the time. Ability to lift more than 50 lbs. ITAR Requirements Applicants must be a U.S. citizen or national, lawful permanent resident, refugee under 8 U.S.C. § 1157, or asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. This position may require access to classified information or restricted U.S. Government sites, systems, or information, depending on the company and applicable U.S. Government requirements. Affirmative Action/EEO Statement Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced by protected status. #J-18808-Ljbffr Front Door Defense