Design 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 Design Engineer to support the mechanical design, component integration, and rapid prototyping of solid rocket motor (SRM) hardware and propulsion subsystems in Bloomington, Indiana.

In this role, you will be responsible for bringing early-stage solid rocket motor concepts to life—from motor cases, nozzles, and igniters to specialized processing and assembly tooling. You will bridge initial product definition and shop-floor execution by developing 3D CAD models, detailed 2D engineering drawings, GD&T disclosures, and Interface Control Documents (ICDs). Working closely with Systems Engineering, Analysis, Manufacturing, Quality, and Test teams, you will ensure fast-turn SRM designs meet rigorous performance, structural/thermal margins, producibility, and explosive safety standards.

Key Responsibilities

Solid Rocket Motor & Component Design

• CAD Modeling & Technical Drawings: Lead the 3D CAD modeling and drafting of complex SRM components, including motor cases, closure assemblies, nozzles, insulation/liners, igniter housings, and secondary structural brackets using PTC Creo or Siemens NX.
• Interface Control & Documentation: Draft and maintain Interface Control Documents (ICDs), Interface Summary Sheets, and drawing tree structures for single motor prototype builds and test integration.
• Design Trade Studies: Perform design trade studies to evaluate material selection, structural joint configurations (e.g., bolted joints, composite/bonded interfaces), and manufacturability vs. weight/performance constraints.
• Tolerance & Assembly Analysis: Perform stacked tolerance analyses using ASME Y14.5 GD&T principles to ensure seamless fit-up and function across motor assemblies and test stand interfaces.

Producibility, Tooling & Cross-Functional Integration

• Design for Producibility (DFM/DFA): Partner with process, tooling, and quality engineers to optimize design disclosures for rapid-turn manufacturing, energetic mixing/casting, and specialized tooling setup.
• Tooling & Ground Support Design: Assist in the design and conception of special tooling, rotation carts, casting fixtures, and static test stand interfaces to support safe, remote-operated energetic handling.
• Technical Milestone Reviews: Develop and present technical design packages for milestone reviews, including Preliminary Design Reviews (PDR), Critical Design Reviews (CDR), and internal engineering board reviews.
• Post-Fire Hardware Evaluation: Participate in post-fire hardware inspections, post-test disassembly, and telemetry/hardware correlation to drive iterative design improvements.

Material Review Board (MRB) & Continuous Improvement

• MRB Engineering Support: Support Material Review Board (MRB) evaluations by evaluating discrepant hardware, performing engineering dispositions (Use-As-Is, Rework, Scrap), and determining structural/functional impacts.
• Root Cause & Anomaly Investigations: Lead or support formal Root Cause Corrective Action (RCCA) investigations for hardware defects, manufacturing escapes, and test anomalies using 5-Why and 8D methodologies.
• Failure Analysis: Utilize Failure Mode and Effects Analysis (FMEA) to identify and mitigate design-inherent failure modes early in the prototyping phase.

Compliance, Safety & Standards

• Explosive & Safety Integration: Design components and tooling in compliance with site-specific explosive safety standards (DoD 4145.26-M), Electrostatic Discharge (ESD) controls, and hazardous location classifications (Class I/II, Div 1/2).
• AS9100 & Drawing Standards : Ensure compliance with AS9100 quality management systems, defense drawing release standards, 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, or a related STEM discipline.
• Minimum of 4+ years of progressive engineering experience in mechanical/propulsion design, with direct experience in solid rocket motors, missile systems, or high-hazard energetic hardware.
• Advanced proficiency in 3D CAD modeling and drafting (PTC Creo or Siemens NX) and PDM/PLM systems (e.g., PTC Windchill).
• Strong working knowledge of ASME Y14.5 GD&T, tolerance stack-up analysis, strength of materials, and precision metal/composite fabrication methods.
• Proven experience preparing complete engineering drawing packages, assembly trees, and interface control documents for aerospace or defense systems.
• Strong verbal and written communication skills with the ability to present complex technical content to multi-disciplinary teams.
• U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

• Master of Science in Mechanical or Aerospace Engineering.
• 6+ years of experience designing solid rocket motor components (nozzles, motor cases, closures, igniters) or energetic processing/test tooling in a startup or defense prime environment.
• Experience performing basic FEA (structural/thermal) using ANSYS, Abaqus, or NASTRAN to guide initial component sizing prior to formal analysis handoff.
• Formal MRB certification with experience dispositioning complex metallic, composite, or bonded hardware.
• Hands-on experience with composite filament winding, metal forging/machining, elastomer/liner application, and energetic mixing/casting tooling.
• Active U.S. DoD Secret or Top Secret Security Clearance.

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

EQUAL OPPORTUNITY EMPLOYER
Prometheus Energetics is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, pregnancy, genetic information, disability, protected veteran status, or any other status protected by applicable federal, state, or local law.