Manufacturing Engineer, Propellant
About The Position
Castelion was founded to restore America’s ability to field advanced weapons at speed and scale. Inspired by the engineering urgency of the WWII and Apollo eras, we combine rapid iteration, vertical integration, and scalable manufacturing to deliver affordable, high-performance strike systems. Our mission: rebuild industrial agility to strengthen national security and outpace evolving threats. We are seeking a Propellant Manufacturing Engineer to lead and execute propellant manufacturing processes for solid rocket motors (SRM) supporting Castelion's 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.
Requirements
- Bachelor's or Master's 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.
Nice To Haves
- 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.
Responsibilities
- Lead and execute propellant manufacturing processes for solid rocket motors (SRM) supporting Castelion's hypersonic strike programs, including Blackbeard.
- Focus on the development, optimization, qualification, and scaling of propellant formulation, mixing, casting, curing, and related processes.
- 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.
- Partner closely with Propulsion Design, Manufacturing, Quality, Automation & Controls, and Test teams to ensure propellant processes meet stringent performance, safety, and producibility requirements.
Benefits
- Meaningful equity for all full-time employees
- Four (4) weeks of paid time off
- Ten (10) company paid holidays
- Medical plans at 100% employee covered and 80% of dependent coverage
- Dental & Vision: 90% employees and 80% for dependents
- FSA/HSA options
- 401k plan
- Paid Parental Leave: Up to 10 weeks for birthing parents, up to 4 weeks for non-birthing parents
- Frequently catered lunches and team meals
- Company-covered meals when extra time or effort is required
- Fully stocked kitchen with unlimited snacks and drinks
- $100 monthly fitness stipend
- Onsite electric vehicle charging
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What This Job Offers
Job Type
Full-time
Career Level
Senior
