Manufacturing Engineer, Solid Rocket Motors

Castelion Corporation•Rio Rancho, NM

7d•Onsite

About The Position

Castelion is building affordable, rapidly producible hypersonic strike weapons for the U.S. military and is establishing R&D manufacturing at its facility in Midland, Texas. The role focuses on developing, optimizing, qualifying, and executing solid rocket motor manufacturing processes and energetic operations. The engineer will lead prototype and research builds, ensure products are manufactured safely and efficiently to high-quality standards, and work with Design, Automation & Controls, Quality, Test, and other Manufacturing Engineers. The position also contributes to new product introduction, continuous improvement, and facility ramp-up. In the first 12 months, the role is expected to establish safe, repeatable solid rocket motor manufacturing processes, including process specifications, work instructions, and explosives SOPs; qualify tooling, equipment, and processes for R&D and low-rate initial production; and execute R&D efforts supporting the Blackbeard program. The position is based at Castelion’s Midland, Texas facility and requires access to ITAR-controlled information. Applicants must be U.S. persons as defined under ITAR and must hold, or be able to obtain and maintain, a U.S. government security clearance. Employment may also be contingent on meeting additional government authorization, citizenship, or eligibility requirements if the position is designated for access to classified information or restricted government sites, systems, or information.

Requirements

Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Materials Science, or a related field.
At least 2 years of manufacturing or mechanical engineering experience.
Demonstrated success developing and scaling manufacturing processes from prototype to low-rate or rate production.
Experience in fast-paced environments, such as aerospace startups.
Hands-on experience building, inspecting, and accepting assemblies.
Proficiency in CAD (SolidWorks or NX), GD&T, tooling and fixture design, process documentation, and nonconformance disposition.
Must be a U.S. person as defined under ITAR to access information and technology controlled under ITAR.
Must hold, or be able to obtain and maintain, a U.S. government security clearance.
Must be able to access applicable export-controlled information without additional export licensing being required.

Nice To Haves

Experience with energetic materials or solid rocket motors.
Working knowledge of explosives safety requirements, hazard analysis, and hazardous process manufacturing.
Prior involvement in facility stand-up, equipment qualification, or production ramp activities.
Experience supporting ITAR-controlled and classified programs.

Responsibilities

Own development and optimization of solid rocket motor manufacturing processes, including propellant mixing and casting, motor integration, and igniter assembly.
Drive Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, control plans, and statistical process control (SPC) to improve yield, reduce cycle time, and lower cost.
Author explosives operating procedures (SOPs) and support process hazard analyses, hazard classification, and explosives site planning for new and modified operations.
Implement electrostatic discharge (ESD) controls and safe handling practices for initiators, bridgewire devices, and other electrically sensitive components.
Support equipment qualification and process validation at the Midland, Texas facility.
Interface with suppliers on materials, tooling, and equipment to resolve issues and improve incoming quality.
Establish safe, repeatable manufacturing processes, with process specifications, work instructions, and explosives SOPs in place.
Qualify tooling, equipment, and processes for R&D and low-rate initial production to inform production-scale manufacturing.
Execute R&D efforts in support of the Blackbeard program.
Lead prototype and research builds and help ensure products are high quality and manufactured safely and efficiently.
Contribute to new product introduction, continuous improvement, and facility ramp-up.