Manufacturing Engineer, Propellant

Why Castelion Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus ownership and excellence are decisive advantages - and were building a world-class team to turn bold ideas into real capability.

This is a rare opportunity to join at an early stage where youll have significant ownership collaborate with exceptional teammates and make a direct measurable impact on our mission and the future of the company - regardless of your function.

Manufacturing Engineer Propellant

We are seeking a Propellant Manufacturing Engineer to lead and execute propellant manufacturing processes for solid rocket motors (SRM) supporting Castelions hypersonic strike programs including Blackbeard. This role focuses on the development optimization qualification and scaling of propellant formulation mixing casting curing and related processes. You will work hands-on with energetic materials in a high-consequence environment driving process reliability yield safety and throughput as we transition from prototype and research builds to high-rate production. Partnering closely with Propulsion Design Manufacturing Quality Automation & Controls and Test teams you will ensure propellant processes meet stringent performance safety and producibility requirements.

Responsibilities

• Own or lead propellant manufacturing processes including ingredient preparation batch mixing vacuum casting grain forming curing and finishing operations.
• Develop document and continuously improve process parameters work instructions and control plans for propellant production.
• Execute Design for Manufacturability (DFM) and process FMEA activities; drive statistical process control (SPC) and yield improvement initiatives.
• Support new product introduction (NPI) by translating propellant formulation and grain design requirements into robust scalable manufacturing processes.
• Perform root-cause analysis and implement corrective/preventive actions for process deviations defects or quality issues. Collaborate with Automation & Controls teams to introduce or improve mixing casting and handling automation while maintaining strict safety and process control.
• Ensure full compliance with energetic materials handling protocols DoD 4145.26-M ATF regulations ITAR and site-specific explosive safety standards.
• Support equipment selection qualification maintenance and process validation for mixers casting systems ovens and related tooling.
• Interface with suppliers on propellant ingredients and intermediate materials; contribute to incoming quality and supplier process improvements.
• Mentor junior engineers and technicians; contribute to training programs and process standardization across production sites.
• Support facility ramp and capability expansion at the Midland TX operations and Project Ranger campus in New Mexico.

Basic Qualifications

• Bachelors or Masters degree in Chemical Engineering Materials Science Manufacturing Engineering Mechanical Engineering or related technical field.
• 5 years of manufacturing or process engineering experience with at least 3 years hands-on work involving solid propellants energetic materials or analogous high-hazard chemical/process manufacturing.
• Demonstrated experience developing or scaling mixing casting or similar batch/process operations in a regulated environment.
• Hands-on experience with propellant or energetic mixing (planetary vertical or similar mixers) vacuum casting and curing processes.
• Strong understanding of propellant rheology ingredient interactions process sensitivity and quality attributes (density voids mechanical properties ballistic performance).
• Proficiency with process documentation statistical tools (Minitab or similar) PFMEA and root-cause methodologies.
• Familiarity with process equipment design/qualification instrumentation and data collection for batch processes.
• Working knowledge of energetic materials safety hazardous location requirements and large-scale chemical handling practices.
• Ability to interpret engineering drawings specifications and material data sheets.

Preferred Skills and Experience

• Direct experience manufacturing solid rocket motor propellants for DoD NASA or commercial space/hypersonic programs.
• Background in fast-paced aerospace or defense production environments (startups or primes).
• Experience scaling processes from laboratory/prototype to low-rate or high-rate production.
• Familiarity with insensitive munitions practices motor case interfaces or propellant-to-liner bonding processes.
• Prior involvement in facility stand-up equipment commissioning or production ramp of energetic materials lines.
• Experience with ITAR-controlled programs and classified manufacturing environments.

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities duties or responsibilities that are required of the employee for this job. Duties responsibilities and activities may change at any time with or without notice.

Additional Eligibility Requirements

This position may require access to classified information or restricted U.S. Government sites systems or information as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization and to satisfy any citizenship or other eligibility requirements imposed by applicable law regulation executive order or government contract requirements. You will be notified if and when such requirements apply.

Affirmative Action/EEO Statement

Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race color religion sex sexual orientation gender identity national origin age disability genetic information protected veteran status or any other characteristic protected by applicable federal state or local law.

Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application participate in the interview process or otherwise participate in the hiring process please contact Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law.

Castelion is committed to fostering a workplace where employment decisions are based on qualifications business needs and the ability to perform the essential functions of the role with or without reasonable accommodation.

EAR/ITAR Requirements

This position requires access to export-controlled information and as such employment (or hiring of a contractor) is contingent upon the candidates ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.

Required Experience:

IC