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Castelion · 2 weeks ago

Senior Manufacturing Engineer - Propellant Mixing & Casting

Torrance, CA

Full-time

Onsite

Senior Level

7+ years exp

Castelion is bringing a new approach to defense development and production, focusing on short, iterative design cycles and modern manufacturing strategies. They are seeking a Senior Manufacturing Engineer to lead the propellant mixing and casting operations for solid rocket motor programs, developing and qualifying processes while driving improvements in yield and safety.

AerospaceGovernmentManufacturingMilitaryNational Security

No H1B

U.S. Citizen Only

Hiring Manager

Andy R.

Responsibilities

Own all technical aspects of propellant mixing and casting operations

Develop and qualify new propellant formulations, mixing procedures, vacuum-casting processes, and cure cycles

Establish process windows, control plans, and critical-to-quality parameters that deliver consistent grain geometry, void-free castings, and predictable ballistic performance

Lead root-cause investigation and corrective-action efforts for casting defects (voids, cracks, unbonded regions, inclusions)

Implement advanced process monitoring (real-time rheology, vacuum sensing, thermal imaging) and in-situ inspection techniques to achieve first-pass yield >95%

Drive labor-hour and material-waste reduction through fixture design, batch-size optimization, automation of material handling, and de-aeration steps

Plan and execute the transition from development-scale mixing to full-rate production

Specify, procure, and commission high-capacity vertical/horizontal mixers, casting pits, vacuum systems, and automated propellant transfer equipment

Develop facility layouts and material-flow designs that support simultaneous multi-program production while maintaining explosive quantity-distance compliance

Author and maintain hazard analyses, SOPs, and explosive safety submissions specific to propellant mixing and casting

Lead process hazard analyses (PHA) and ensure all equipment and procedures incorporate quantity-distance, ESD, and personnel exposure limits

Champion rigorous change control for any formulation or process modification

Serve as the primary propellant subject-matter expert to Design Engineering during grain-design trades and liner/insulator compatibility reviews

Support new product introduction by generating PFMEAs, performing qualification casting runs, and establishing non-destructive evaluation criteria (ultrasonic, X-ray CT) for cast grains

Interface directly with Quality, EHS, and customers on non-conformances and anomaly resolution

Design or specify reusable casting mandrels, vacuum systems, transfer pots, and automated de-molding systems

Integrate digital tools (MES recipes, real-time data acquisition, predictive viscosity modeling) to reduce operator dependency and enable 24/7 unattended curing

Qualification

Chemical EngineeringProcess DevelopmentPropellant MixingVacuum CastingSafety LeadershipAutomation ScriptingNDE MethodsCross-Functional CollaborationCreative Problem SolvingClear Communication

Required

Bachelors degree in Chemical Engineering, Mechanical Engineering, Aerospace Engineering, or related field

Minimum 7 years of direct hands-on experience in process sensitive manufacturing fields, ideally within the energetics space

Preferred

Track record of scaling composite propellant production

Hands on experience specifically in propellant mixing, vacuum casting, and case-bonded grain production or equivalent

Deep knowledge of propellant formulations, isocyanate curing chemistry, pot-life management, rheological modeling, and void-prediction/mitigation techniques

Hands-on experience qualifying new propellant formulations and casting processes for DoD programs (tactical, missile defense, strategic, or space launch)

Familiarity with advanced NDE methods for cast energetics (phased-array ultrasound, digital radiography, CT scanning)

Prior work in facilities holding ATF licenses and DoD explosive safety approvals

Strong aptitude for scripting/automation (Python, LabVIEW) and integrating sensors into legacy energetics equipment

Ability to thrive in a fast-paced startup environment with aggressive schedules and evolving requirements