Project Engineer

Prometheus Energetics•Bloomington, IN

4d•Onsite

About The Position

Prometheus Energetics is seeking an experienced Project Engineer to lead a small team in setting up and operating a rapid prototyping and test facility in Bloomington, Indiana, dedicated to fabricating and testing single solid rocket motors (SRMs). In this high-impact role, you will lead a nimble engineering team responsible for bringing a greenfield energetic lab, build facility, and test infrastructure online. You will bridge early-stage motor design and rapid shop-floor execution—overseeing everything from facility setup, specialized tooling, and equipment commissioning to energetic mixing, casting, motor assembly, and static test execution. Working closely with Engineering, Operations, Quality, EHS, and technology-transfer partners, you will ensure fast-turn prototype builds and static firings meet all technical, performance, and high-hazard safety requirements.

Requirements

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Chemical Engineering, or a related technical discipline. Demonstrated work history may substitute for a degree.
Minimum of 6+ years of progressive engineering experience in solid rocket propulsion, pyrotechnics, or hazardous energetic materials processing, including experience leading small technical teams or project workflows.
Proficiency in 3D CAD software (e.g., PTC Creo, Siemens NX, SolidWorks) and Product Data Management (PDM/PLM) systems (e.g., Windchill).
Solid understanding of Geometric Dimensioning and Tolerancing (GD&T per ASME Y14.5), structural strength of materials, and precision metal/composite fabrication methods.
Proven experience generating assembly routers, process flow diagrams, PFMEAs, and detailed work instructions for complex solid rocket motor hardware.
Deep knowledge of DoD energetics safety standards (DoD 4145.26-M), Process Safety Management (PSM), and hazardous location classifications (Class I/II, Div 1/2).
Excellent written, verbal, analytical, and executive communication skills.
U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Nice To Haves

Master of Science in Mechanical Engineering, Aerospace Engineering, Chemical Engineering, or Engineering Management.
Minimum of 10+ years of progressive engineering experience in solid rocket propulsion, pyrotechnics, or hazardous energetic materials processing, including experience leading small technical teams or project workflows.
Direct experience standing up rapid-prototyping, pilot manufacturing, or ground-testing facilities for solid rocket motors in a defense startup or expansion environment.
Hands-on familiarity with energetic mixing/casting equipment, remote-operated tooling/robotics, static test stands, thrust-termination systems, and high-speed data acquisition (DAQ) equipment.
Background in developing standard operating procedures (SOPs), hazard analyses (PHA/HAZOP), static test safety protocols, and Explosive Facility Safety Site Plans.
ASQ certifications (CQE, CQA), formal GD&T certification, or Six Sigma Green/Black Belt credentials.
Active U.S. Secret Security Clearance or higher.

Responsibilities

Lead technical execution for the layout, tooling integration, and installation of energetic processing and test equipment (mixers, casting chambers, rotation carts, remote-handling systems, and static test stands) for single rocket motor builds.
Establish, prove out, and sustain rapid-turn manufacturing processes, operational routers, tooling sheets, and detailed Standard Work Instructions (SWIs) for propellant handling, motor assembly, casting/curing, and static test prep.
Define capital equipment and test instrumentation specifications, evaluate vendor proposals, and manage full-lifecycle acquisition, site acceptance testing (SAT), and equipment commissioning prior to active energetic processing and testing.
Directly lead a small, agile team of tooling, process, and test engineers through initial facility buildout, process qualification, and rapid motor fabrication/test cycles.
Drive project schedules, milestone deliverables, technical risk management, and budget allocation for facility capital equipment, prototype tooling, and test instrumentation.
Serve as the primary technical interface with prototype lab chemists, test technicians, and EHS teams to establish safe operational workflows, shop-floor troubleshooting guidelines, and rapid-iteration feedback loops between motor builds and test firings.
Act as a voting member on the Material Review Board (MRB) to evaluate single-motor prototype non-conformances, perform engineering dispositions, and implement containment protocols.
Lead formal Root Cause Corrective Action (RCCA) investigations for build anomalies, test deviations, process escapes, and tooling wear using 5-Why, Fishbone, and 8D methodologies.
Apply Lean/Six Sigma practices, Process Failure Mode and Effects Analysis (PFMEA), and mistake-proofing (poka-yoke) controls early in the prototyping and testing phase to simplify future transition into high-rate production.
Partner with Environmental Health & Safety (EHS) and Energetics Safety teams to strictly enforce site-specific explosive safety standards (DoD 4145.26-M), Electrostatic Discharge (ESD) controls, NFPA 495/652, and OSHA Process Safety Management (PSM) guidelines across build and test operations.
Establish site classification standards, quantity-distance (Q-D) criteria, grounding/bonding requirements, and blast mitigation/suppression controls for rapid prototyping and static testing.
Ensure full compliance with AS9100 quality standards, federal ammunition and explosives regulations, and trade compliance protocols (ITAR / EAR).
Establish actionable dashboards, review tooling performance with engineering and operational leadership, and hold owners accountable for recovery and improvement plans.
Lead small team capability development, technical mentorship, and rapid-response project support effectiveness.