Design Engineer

PROMETHEUS ENERGETICS, LLC•Bloomington, IN

21d•Onsite

About The Position

Prometheus Energetics is seeking an experienced Design Engineer to support mechanical design, component integration, and rapid prototyping of solid rocket motor (SRM) hardware and propulsion subsystems in Bloomington, Indiana. The role brings early-stage SRM concepts into production-ready designs, including motor cases, nozzles, igniters, and specialized processing and assembly tooling. It bridges product definition and shop-floor execution through 3D CAD models, detailed 2D engineering drawings, GD&T disclosures, and Interface Control Documents (ICDs). The Design Engineer works with Systems Engineering, Analysis, Manufacturing, Quality, and Test teams to deliver fast-turn designs that meet performance, structural and thermal margin, producibility, and explosive-safety requirements. The role also supports design reviews, prototype and test activities, MRB dispositions, root-cause investigations, compliance, and performance tracking. Work takes place in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas with enhanced safety and security controls. Periodic travel may be required.

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 with PTC Creo or Siemens NX, and experience with PDM/PLM systems such as PTC Windchill.
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.
Ability to wear required PPE and comply with site safety, explosive-safety, 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.

Nice To Haves

Master of Science in Mechanical or Aerospace Engineering.
Six or more years of experience designing solid rocket motor components, such as nozzles, motor cases, closures, or igniters, 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 SRM 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.
Perform design trade studies for material selection, structural joint configurations, manufacturability, weight, and performance.
Perform tolerance stack-up analyses using ASME Y14.5 GD&T principles for motor assemblies and test stand interfaces.
Partner with process, tooling, and quality engineers to optimize designs for rapid-turn manufacturing, energetic mixing and casting, and specialized tooling setup.
Assist with 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 (PDR), Critical Design Reviews (CDR), and internal engineering board reviews.
Participate in post-fire hardware inspections, post-test disassembly, and telemetry and hardware correlation to drive design improvements.
Support MRB evaluations by assessing discrepant hardware, preparing Use-As-Is, Rework, or Scrap dispositions, and determining structural and functional impacts.
Lead or support Root Cause Corrective Action (RCCA) investigations for 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.
Design components and tooling in accordance with applicable explosive-safety, ESD, hazardous-location, quality, drawing-release, and trade-compliance requirements.
Establish actionable dashboards and review tooling and operational performance with engineering and operational leadership; hold owners accountable for recovery and improvement plans.
Track and support performance measures related to prototype milestones, test stand commissioning, design-to-release compliance, prototype iteration and build-to-test speed, vendor quality and delivery, drawing compliance, yield, scrap and rework, RCCA effectiveness, equipment proof-load and calibration, preventive maintenance, safety compliance, team development, and project support.
Wear required PPE, comply with site safety and access-control requirements, move throughout the manufacturing site, inspect physical tooling, participate in shop-floor audits, and occasionally lift up to 25 pounds.
Maintain regular, reliable attendance and travel periodically to vendor machine shops, secondary company facilities, or customer sites when required.