Sr. Materials & Process Engineer, Energetic Materials

Why Castelion, Why Now Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability. This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.

About the role

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. This individual will be responsible for 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 successful candidate will bring strong expertise in the characterization of polymers, elastomers, or other viscoelastic materials, with experience translating material behavior into engineering requirements, specifications, and qualification programs. Prior experience with energetic materials or solid propellants is preferred but not required.

Responsibilities

• Establish test methods to characterize the mechanical, viscoelastic, thermal, and environmental behavior of propellant materials, including the effects of temperature, strain rate, aging, and processing conditions.
• Establish qualification and acceptance testing for raw materials and cast propellant, including material specifications, test plans, acceptance criteria, and environmental qualification requirements.
• Develop a systematic approach to investigating material and process-related failures using mechanical testing, microscopy, thermal analysis, and other characterization techniques to identify root causes and drive corrective actions.
• Lead characterization of propellant and related polymeric material systems using mechanical testing, DMA, rheometry, DSC/T