Propulsion Engineer (Solid Rocket Motor Ballistics)

Castelion Corporation • Torrance, CA

2d

About The Position

Castelion is seeking a solid rocket motor ballistician to own motor performance predictions and help deliver propulsion systems at speed and scale. The role emphasizes technically sound designs that meet aggressive schedule, affordability, and production goals. The engineer will lead propulsion hardware architecture and design, perform analysis and testing, and work across engineering and manufacturing teams to integrate reliable systems with the vehicle. The position may involve access to classified information or restricted U.S. Government sites, systems, or information; if applicable, employment may depend on obtaining and maintaining required authorization and meeting legal or contract eligibility requirements. The position also requires access to export-controlled information, so employment is contingent on the candidate being able to access applicable information without additional export licensing.

Requirements

• Bachelor’s, master’s, or PhD in aerospace engineering, mechanical engineering, or a related field.
• At least 2 years of experience in rocket propulsion design, analysis, and testing for aerospace or defense applications.
• Strong background in solid rocket motor design, including internal ballistics, grain design, ignitors, and nozzle performance.
• Experience with propulsion testing, including static-fire test setup, instrumentation, and data analysis.
• Familiarity with structural and thermal design considerations for high-temperature, high-pressure systems.
• Proficiency with analysis and modeling tools such as MATLAB, SPP, or equivalent.
• Experience with hardware build, integration, and troubleshooting in a lab or test environment.
• Strong problem-solving mindset and ability to thrive in a fast-paced, hardware-rich environment with a high test cadence.
• Willing and able to work extended hours and/or weekends with minimal notification to meet critical deadlines leading up to major milestones.
• Able to travel up to 30% on an ongoing basis.
• Ability to access applicable export-controlled information without additional export licensing.

Nice To Haves

• Experience with preliminary or conceptual solid rocket motor grain design from performance requirements.
• Experience with pyrotechnic and pyrogenic ignition systems and characterizing ignitor performance.
• Experience with grain and nozzle optimization for tactical solid rocket motors.
• Experience correlating analytical models with physical test data.
• Experience with aerospace, hypersonic, launch vehicle, spacecraft, or other high-performance flight hardware.
• Experience establishing engineering standards or methodologies.
• Demonstrated ability to mentor and technically develop engineers.
• Experience with composites, coatings, finishes, and advanced manufacturing processes.

Responsibilities

• Design and develop rocket motor systems, including grain geometry, case structures, insulation, and nozzle assemblies.
• Lead the architecture and detailed design of propulsion hardware to meet performance, structural, and thermal requirements.
• Perform internal ballistics, thermal, and structural analyses to ensure motor performance and reliability under extreme operating conditions.
• Advance Castelion’s internal analysis capabilities and correlate predictions with tests for solid rocket motor propellant and BKNO3 ignition systems.
• Coordinate with structures, thermal, GNC, and manufacturing teams to integrate propulsion systems with the vehicle.
• Support propellant selection, processing, and characterization with materials and manufacturing teams.
• Plan and execute static-fire tests and development test campaigns, including instrumentation, data collection, and post-test analysis.
• Conduct failure analysis and root-cause investigations, driving design improvements and risk reduction.
• Define and execute qualification and flight-test plans, translating results into system-level improvements.
• Optimize designs for performance, mass, manufacturability, and operational reliability.
• Mentor junior engineers and contribute to best practices in propulsion system design and testing.
• Partner with program leadership on technical trades aligned with mission success.
• Work extended hours and/or weekends with minimal notification when needed to meet critical deadlines before major milestones.
• Travel up to 30% on an ongoing basis.

What This Job Offers

• Job Type: Full-time
• Career Level: Entry Level