SRM - Director of Engineering (Start Up Div in VA) with Security Clearance

About the role

Avio USA is building a subsidiary from scratch in the USA and is seeking a Director of Engineering as employee #2 and reporting directly to the CEO. This role will be hands-on and involve building something from the ground-up.

Responsibilities

• Greenfield Facility Leadership: Architect and oversee the construction, layout, and commissioning of a new U.S.-based SRM manufacturing plant from the ground up. Ensure the facility meets all AS9100 and defense-grade safety/security standards.
• Partnership Management: Work closely with CEO and serve as one of the primary technical points of contact for RTX (Raytheon). Navigate the $26M+ contract requirements, ensuring all milestones - from Critical Design Review (CDR) to qualification—are met on time and within spec. This will include partnering with third-party outsourced SRM manufacturers and Boston Consulting leaders to continue to complete and win bids at all phases of the MK 104 project.
• Production Scaling: Transition the Mk 104 from design and engineering into high-rate manufacturing. Implement advanced automated processes for propellant mixing, casting, and motor integration.
• Team Building & Leading: Recruit, hire, mentor, and lead a multi-disciplinary engineering team (Chemical, Mechanical, Aerospace, and Quality) dedicated to SRM production. Will be expected to hire 5 SRM Engineers within 3-4 months.
• Regulatory & Security Compliance: Ensure all operations comply with ITAR, EAR, and DoD security protocols (e.g., CMMC). Oversee the hazardous material handling and safety protocols inherent to solid propellant manufacturing.
• Strategic Sourcing: Collaborate with supply chain teams to secure long-lead materials and build a resilient domestic supplier base for SRM components.

Requirements

• Must have a Technical Degree and 15+ years in related aerospace/defense engineering, with at least 5 years in a senior leadership role specifically focused on manufacturing Solid Rocket Motors (SRM).
• Proven track record of taking a complex SRM propulsion system through the full lifecycle - from end-to-end, from qualification to large-scale production.
• Greenfield experience having set up or greatly overhauled a new manufacturing line (or facility) from scratch, including equipment selection (planetary mixers, X-ray inspection, winding machines, etc.), and hiring SRM Engineers.
• Must be willing to travel regularly to Arlington, VA to partner with CEO. Must be willing to relocate to Hurt, VA area within 1-2 years to help get the new manufacturing facility up and running and staffed.
• MUST BE A US CITIZEN WITH THE ABILITY TO OBTAIN A U.S. SECRET SECURITY CLEARANCE FOR ITAR RESTRICTIONS.
• Experience with several key technical skills, including SRM – Solid Rocket Motor Propulsion, ANSYS mechanical (or Abaqus), FEA (Finite Element Analysis) for Nozzle / Propellant / Grain / Thermal / High Temp / High Pressure / SolidWorks or Siemens NX, Testing (static fire, ground test), and Structural and Thermal analysis.
• Hands-on experience with Propellant Chemistry or energetic material handling.
• Knowledge of Composite Pressure Vessel (COPV) design and filament winding.
• Familiarity with Insensitive Munitions (IM) protocols.
• Experience in several other domains, including Structural Components, SRM Performance, Structure Dynamics, Extreme Temperature Components, Materials and Process, Supply Chain / Procurement, and Quality Assurance.

Benefits

The position offers a competitive salary and benefits package, including a U.S. Secret Security Clearance for ITAR restrictions.

Pay

$133,685 per year

Schedule

Initially remote, then relocating to Hurt, VA within 1-2 years to help guide the construction of the new facility. Must be willing to travel to Arlington, VA frequently in the beginning, then one week a month.