Senior Energetics Formulation Chemist / Engineer (Hauppauge)

Solid Rocket Motor Energetics • Scale-Up • Manufacturing Capability • Testing Methodology & Executive

Position Overview

iRocket is seeking a senior Energetics Formulation Chemist or Engineer to lead the formulation, development, scale-up, and manufacturing transition of energetic materials for solid rocket motor applications. The ideal candidate brings strong practical experience in propellant formulation and processing, understands the relationship between formulation, processing, performance, aging, and safety, and can translate customer requirements into repeatable production capability.

This role is intended for a technical leader who can develop both the energetic formulation and the manufacturing capability required to safety produce requirements materials both using traditional and non-traditional manufacturing at scale. Requires work in Long Island, Texas and Indiana, so employee must be willing to travel for extended times.

Key Responsibilities

• Lead formulation and development of solid rocket motor propellants and related energetic material systems, including ingredient selection, formulation optimization, mixing, casting, cure, and test.
• Plan and execute formulation experiments, characterize material and ballistic performance, analyze test data, troubleshoot anomalies, and drive iterative improvements.
• Develop and mature processes from laboratory or pilot scale through repeatable manufacturing, with emphasis on producibility, quality, safety, cost, and throughput.
• Define requirements and support the design, layout, equipment selection, commissioning, and operational readiness of energetic-material manufacturing and processing facilities.
• Develop manufacturing instructions, process controls, specifications, acceptance criteria, and technical documentation supporting safe and repeatable production.
• Work closely with SRM design, manufacturing, test, quality, and program personnel to ensure energetic-material characteristics are integrated into motor design and performance.
• Support hazard analyses, energetic-material handling practices, process safety reviews, environmental/operational controls, and applicable regulatory and explosives-safety requirements.
• Mentor technical staff and serve as a subject-matter expert for energetics formulation, processing, scale-up, and manufacturing readiness.

Required Qualifications

Minimum of Bachelor’s but preferred advanced degree (M.S. or Ph.D.) in chemistry, chemical engineering, materials science, or a closely related technical field.

Minimum 5 years of directly relevant professional experience in energetic materials, solid propellants, or solid rocket motor propulsion; 10+ years strongly preferred.

Demonstrated hands-on experience developing and processing solid rocket motor propellant formulations and transitioning formulations toward production.

Experience with energetic-material manufacturing equipment, facility/process development, production scale-up, and safe operations.

Ability to lead technical problem solving independently while collaborating effectively across multidisciplinary engineering and manufacturing teams.

Highly Desired Experience

• Propellant systems formulation, burn-rate tailoring, mechanical properties, rheology, cure chemistry, aging/life assessment, insensitive-munitions considerations, and/or performance characterization.
• Design or startup of energetic-material laboratories, pilot lines, or production facilities, including equipment specification and process-flow development.
• Experience supporting static-fire testing, failure/anomaly investigation, qualification, production readiness, and configuration-controlled technical data.
• Experience in a rapid-development environment where technical rigor and disciplined safety are paired with aggressive hardware schedules.