Design Engineer

Prometheus Energetics•Bloomington, IN

8d•Onsite

About The Position

Prometheus Energetics is seeking an experienced Design Engineer in Bloomington, Indiana, to support mechanical design, component integration, and rapid prototyping of solid rocket motor hardware and propulsion subsystems. The engineer will develop early-stage concepts into detailed designs for motor cases, nozzles, igniters, specialized processing equipment, and assembly tooling, bridging product definition and shop-floor execution. Work includes 3D CAD models, 2D engineering drawings, GD&T disclosures, and Interface Control Documents (ICDs), with attention to performance, structural and thermal margins, producibility, and explosive safety. The role collaborates with Systems Engineering, Analysis, Manufacturing, Quality, and Test teams. It also supports design reviews, prototype testing and post-fire inspections, material review and disposition, failure investigations, and continuous improvement. The position includes establishing performance dashboards and reviewing tooling, prototype, quality, schedule, safety, and operational measures with engineering and operational leadership. Work takes place in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas with enhanced safety and security controls. Regular reliable attendance is required. Periodic travel to vendor machine shops, company facilities, or customer sites may be needed during startup, tool qualification, or critical production events.

Requirements

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related STEM discipline.
At least 4 years of progressive engineering experience in mechanical or propulsion design, with direct experience in solid rocket motors, missile systems, or high-hazard energetic hardware.
Advanced proficiency in 3D CAD modeling and drafting using PTC Creo or Siemens NX, and experience with PDM/PLM systems such as PTC Windchill.
Strong working knowledge of ASME Y14.5 GD&T, tolerance stack-up analysis, strength of materials, and precision metal or composite fabrication methods.
Experience preparing complete engineering drawing packages, assembly trees, and interface control documents for aerospace or defense systems.
Strong verbal and written communication skills, including the ability to present complex technical content to multidisciplinary teams.
U.S. citizenship and ability to obtain and maintain a U.S. Government Secret Security Clearance.

Nice To Haves

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

Responsibilities

Lead 3D CAD modeling and drafting of solid rocket motor components, including motor cases, closure assemblies, nozzles, insulation and liners, igniter housings, and secondary structural brackets using PTC Creo or Siemens NX.
Draft and maintain Interface Control Documents (ICDs), Interface Summary Sheets, and drawing tree structures for prototype builds and test integration.
Conduct design trade studies involving material selection, structural joint configurations, manufacturability, weight, and performance.
Perform stacked tolerance analyses using ASME Y14.5 GD&T principles for motor assemblies and test stand interfaces.
Collaborate with process, tooling, and quality engineers to improve designs for manufacturability and assembly, rapid-turn manufacturing, energetic mixing and casting, and tooling setup.
Assist with the design of special tooling, rotation carts, casting fixtures, and static test stand interfaces for safe, remote-operated energetic handling.
Develop and present technical design packages for Preliminary Design Reviews (PDRs), Critical Design Reviews (CDRs), and internal engineering board reviews.
Participate in post-fire hardware inspections, post-test disassembly, and telemetry and hardware correlation to support iterative design improvements.
Support Material Review Board (MRB) evaluations by assessing discrepant hardware, recommending Use-As-Is, Rework, or Scrap dispositions, and determining structural and functional impacts.
Lead or support Root Cause Corrective Action (RCCA) investigations into hardware defects, manufacturing escapes, and test anomalies using 5-Why and 8D methods.
Use Failure Mode and Effects Analysis (FMEA) to identify and mitigate design-inherent failure modes during prototyping.
Ensure component and tooling designs comply with site-specific explosive safety standards, ESD controls, and hazardous location classifications.
Ensure compliance with AS9100 quality systems, defense drawing release standards, and ITAR/EAR trade compliance protocols.
Establish actionable dashboards and review tooling performance with engineering and operational leadership; hold owners accountable for recovery and improvement plans.
Monitor measures including prototype and test-stand schedules, design-to-release compliance, prototype iteration and build-to-test cycle times, vendor quality and delivery, drawing compliance, yield, scrap and rework, RCCA effectiveness, equipment proof-load and calibration, preventive maintenance, explosive safety, ESD and ergonomic compliance, and team capability and mentorship.