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Castelion was founded to restore America’s ability to field advanced weapons at speed and scale. Inspired by the engineering urgency of the WWII and Apollo eras, we combine rapid iteration, vertical integration, and scalable manufacturing to deliver affordable, high-performance strike systems. Our mission: rebuild industrial agility to strengthen national security and outpace evolving threats.
About the Role:
We are seeking a Propellant Manufacturing Engineer to lead and execute propellant manufacturing processes for solid rocket motors (SRM) supporting Castelion's hypersonic strike programs, including Blackbeard. This role focuses on the development, optimization, qualification, and scaling of propellant formulation, mixing, casting, curing, and related processes. You will work hands-on with energetic materials in a high-consequence environment, driving process reliability, yield, safety, and throughput as we transition from prototype and research builds to high-rate production. Partnering closely with Propulsion Design, Manufacturing, Quality, Automation & Controls, and Test teams, you will ensure propellant processes meet stringent performance, safety, and producibility requirements.
Requirements
Basic Qualifications
- Bachelor's or Master's degree in Chemical Engineering, Materials Science, Manufacturing Engineering, Mechanical Engineering, or related technical field.
- 5+ years of manufacturing or process engineering experience, with at least 3+ years hands-on work involving solid propellants, energetic materials, or analogous high-hazard chemical/process manufacturing.
- Demonstrated experience developing or scaling mixing, casting, or similar batch/process operations in a regulated environment.
- Hands-on experience with propellant or energetic mixing (planetary, vertical, or similar mixers), vacuum casting, and curing processes.
- Strong understanding of propellant rheology, ingredient interactions, process sensitivity, and quality attributes (density, voids, mechanical properties, ballistic performance).
- Proficiency with process documentation, statistical tools (Minitab or similar), PFMEA, and root-cause methodologies.
- Familiarity with process equipment design/qualification, instrumentation, and data collection for batch processes.
- Working knowledge of energetic materials safety, hazardous location requirements, and large-scale chemical handling practices.
- Ability to interpret engineering drawings, specifications, and material data sheets.
Preferred Skills and Experience
- Direct experience manufacturing solid rocket motor propellants for DoD, NASA, or commercial space/hypersonic programs.
- Background in fast-paced aerospace or defense production environments (startups or primes).
- Experience scaling processes from laboratory/prototype to low-rate or high-rate production.
- Familiarity with insensitive munitions practices, motor case interfaces, or propellant-to-liner bonding processes.
- Prior involvement in facility stand-up, equipment commissioning, or production ramp of energetic materials lines.
- Experience with ITAR-controlled programs and classified manufacturing environments.
Benefits
- Employee Equity: Meaningful equity for all full-time employees - share value has increased 150x in three years
- Personal Time Off: Four (4) weeks of paid time off to unplug, reset, and come back sharp—velocity matters, burnout doesn't
- Company Paid Holidays: Ten (10) company paid holidays
- Medical: We offer plans at 100% employee covered and 80% of dependent coverage
- Dental & Vision: We cover 90% employees and 80% for dependents to ensure you and your family have access to quality preventive and ongoing care
- FSA/HSA: To support long-term health and financial resilience, we offer FSA and HSA options that allow employees to set aside pre-tax dollars for eligible medical and dependent care expenses
- Retirement: 401k plan offered to support long term financial growth along side high-impact, high-velocity work
- Paid Parental Leave: We support growing families with meaningful time to bond and recover. Birthing parents are eligible for up to 10 weeks of paid leave, while non-birthing parents may take up to 4 weeks of paid leave. This time can be used for pre-natal care, pregnancy, childbirth, and related medical needs—ensuring every parent has the support they need during this important life moment.8-weeks of paid parental leave for all parents. Additional paid pregnancy leave for CA employees
- Meals & Catering: Frequently catered lunches and team meals, plus company-covered meals when extra time or effort is required
- Snacks & Beverages: Fully stocked kitchen with unlimited snacks and drinks to keep you fueled throughout the day
- Performance & Fitness: $100 monthly fitness stipend to support peak performance and health, both inside and outside of work
- EV Charging: Onsite electric vehicle charging available for employees
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