Senior Materials & Process Engineer, Propellant Mix & Cast

About the role

Castelion is bringing a new approach to defense development and production, focusing on short, iterative design cycles, rapid testing, and modern commercial manufacturing strategies for production at scale. The company designs, builds, and tests next‑generation long‑range strike weapons systems to give America and its Allies a definitive edge and deter future conflicts. The Senior Materials & Process Engineer, Propellant Mix & Cast will serve as the technical authority for solid rocket motor propellant, developing, qualifying, and scaling propellant formulations and manufacturing processes to meet performance, production rate, and safety requirements.

Responsibilities

• Serve as the subject‑matter expert for energetic materials, providing guidance on processing conditions, propellant qualification, and safety standards.
• Partner with Manufacturing Engineering and Propulsion Engineering teams to scale propellant mixing and casting operations from development to production.
• Implement quality‑assurance and qualification‑testing protocols to ensure raw‑material consistency, performance, and reliability.
• Ensure compliance with applicable energetic‑material standards and handling requirements (ISO, MIL, DOT).
• Develop and maintain material specifications, process controls, and test plans.
• Support root‑cause investigations and continuous‑improvement initiatives related to propellant performance, manufacturability, and safety.

Basic Qualifications

• Bachelor’s degree in chemistry, chemical engineering, materials science/engineering, or a related discipline.
• 5+ years of experience working with energetic materials, preferably within the aerospace industry.
• Experience with propellant characterization techniques including mechanical testing, impact, static, burn‑rate, and impulse testing.
• Excellent written and verbal communication skills.
• Authorization to work in the U.S. and compliance with ITAR eligibility requirements.

Preferred Skills and Experience

• Master’s degree in chemistry, chemical engineering, materials science/engineering, or a related discipline.

Additional Requirements

• Willingness to work extended hours and/or weekends as needed.
• Ability to travel up to 20%.

Leadership Qualities

• Bias to action and creative problem solving; questioning assumptions to generate breakthrough ideas.
• Ability to import processes, concepts, or materials from other industries to achieve efficiency gains.
• Capability to resolve minor development issues independently.
• High commitment and initiative with a genuine passion for Castelion’s mission.
• Comfort operating in a fast‑paced, autonomous, and demanding environment.
• Strong sense of accountability, integrity, and clear communication.
• Proactive communication of blockers; trusted voice with regulators, suppliers, gatekeepers, and customers.
• Skilled at managing stakeholder relationships tactfully to achieve desired outcomes without compromising relationships.

Benefits

• Long‑term stock incentives.
• Comprehensive medical, vision, and dental insurance.
• Four weeks of paid time off per year.

ITAR Eligibility

• U.S. citizen or national.
• U.S. lawful permanent resident (green card holder).
• Refugee under 8 U.S.C. § 1157.
• Asylee under 8 U.S.C. § 1158.
• Or eligible to obtain the required authorizations from the U.S. Department of State.