Sr. Materials & Process Engineer, Energetic Materials

Castelion Corporation•Torrance, NM

About The Position

Castelion is seeking an experienced Materials & Process Engineer to lead the characterization, qualification, and failure analysis of solid rocket motor propellants and related material systems. The role focuses on developing a fundamental understanding of propellant material behavior, establishing characterization and qualification methodologies, and investigating material- and process-related failures to support reliable propulsion hardware. The engineer will apply expertise in characterizing polymers, elastomers, or other viscoelastic materials and translate material behavior into engineering requirements, specifications, and qualification programs. Prior experience with energetic materials or solid propellants is preferred but not required. The position is based in Torrance, California, or Rio Rancho, New Mexico, and reports to the Director of Materials Engineering. For 2026, key outcomes include establishing test methods for propellant mechanical, viscoelastic, thermal, and environmental behavior; setting up qualification and acceptance testing for raw materials and cast propellant; and developing a systematic approach to investigating material- and process-related failures and driving corrective actions. The position may require access to classified information or restricted U.S. Government sites, systems, or information. If designated, employment may depend on obtaining and maintaining the required U.S. Government security clearance or other authorization and satisfying applicable eligibility requirements. The position requires access to export-controlled information, so employment is contingent on the candidate being able to access applicable information without additional export licensing. Castelion is an Equal Opportunity Employer and provides reasonable accommodations to qualified individuals with disabilities during the application and hiring process.

Requirements

Bachelor’s degree in materials science/engineering, chemistry, or a related discipline.
5+ years of experience working with polymer characterization, preferably within the aerospace industry.
Prior experience with propellant characterization techniques including mechanical testing, impact, static, burn-rate, and impulse testing.
Excellent written and verbal communication skills.
Must be authorized to work in the U.S. and comply with ITAR eligibility requirements.
Must be able to access applicable export-controlled information without additional export licensing.
If the position is designated as requiring it, must be able to obtain and maintain the required U.S. Government security clearance or other authorization and satisfy applicable eligibility requirements.

Nice To Haves

Experience with energetic materials or solid propellants is preferred but not required.

Responsibilities

Lead characterization of propellant and related polymeric material systems using mechanical testing, DMA, rheometry, DSC/TGA, microscopy, and other relevant techniques.
Develop test methods to understand material behavior across relevant temperatures, strain rates, aging conditions, and operational environments.
Develop and execute material qualification and acceptance testing programs for raw materials and cast propellant.
Lead failure analysis and root-cause investigations related to material performance, processing, and manufacturing defects.
Develop and maintain material specifications, process controls, test plans, and acceptance criteria.
Partner with Propulsion and Manufacturing Engineering to translate characterization results into material selection, processing requirements, and design inputs.
Support manufacturing scale-up by identifying relationships between processing conditions, material structure, and resulting properties and performance.
Ensure material testing and qualification activities comply with applicable material, handling, and safety requirements.