Senior Manufacturing Engineer, Igniters and Pyrotechnics

Castelion Corporation•Rio Rancho, NM

35d

About The Position

Castelion is seeking a Senior Manufacturing Engineer to own manufacturing processes for igniters and pyrotechnic devices supporting Castelion’s hypersonic strike weapons, including the Blackbeard program. This role focuses on developing, optimizing, qualifying, and executing production processes for solid rocket motor igniters, initiators, gas generators, and other pyrotechnic devices. You will drive process improvements, lead the transition from prototype and research builds to scalable high-rate production, and ensure products are high quality and manufactured safely and efficiently. You will work closely with Design, Automation & Controls, Quality, Test, and fellow Manufacturing Engineers to ensure your products integrate with the larger system, and you will contribute to new product introduction, continuous improvement, and facility ramp-up at our manufacturing sites.

Requirements

Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Materials Science, or related field.
7+ years of manufacturing engineering experience, including 3+ years of hands-on work processing energetic materials or manufacturing igniters, initiators, or other pyrotechnic devices in aerospace or defense.
Demonstrated success developing and scaling manufacturing processes from prototype to low-rate or rate production.
Hands-on experience building, inspecting, and accepting complex electromechanical and energetic assemblies.
Proficiency in CAD (SolidWorks or NX), GD&T, tooling/fixture design, process documentation, and nonconformance disposition.
Working knowledge of explosives safety requirements, hazard analysis, and hazardous process manufacturing.
Ability to obtain and maintain the required U.S. Government security clearance or other government authorization.
Ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.

Responsibilities

Own development and optimization of igniter and pyrotechnic manufacturing processes, including piece part manufacturing, pyrotechnic composition weighing, blending, and pressing/consolidation, device assembly, and sealing (including hermetic sealing).
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.
Define and execute inspection and acceptance strategies in partnership with Quality and Test, including radiographic inspection (X-ray/N-ray), bridgewire resistance testing, lot acceptance testing, and closed-bomb testing.
Support new product introduction (NPI) and design change implementation by providing manufacturing input and executing first article inspections and process qualifications.
Perform root-cause analysis and lead corrective/preventive actions for process issues and defects.
Collaborate with Automation & Controls to implement robotics, vision systems, and digital tools (MES, data analytics) for improved efficiency and traceability.
Author and maintain work instructions, process documentation, and training materials; document and disposition nonconformances; mentor junior manufacturing engineers.
Ensure compliance with explosives safety and regulatory requirements, including DoDM 4145.26, DESR 6055.09, DOT hazardous materials regulations (49 CFR), and ITAR.
Support equipment qualification, process validation, and production ramp at the Midland, TX facility and the Project Ranger campus in New Mexico.
Interface with suppliers on materials, tooling, and equipment to resolve issues and improve incoming quality.