Hazardous Materials Packaging Specialist

Voyager Energetics is seeking a Hazardous Materials Packaging Specialist to design, develop, and implement packaging solutions that protect energetic materials, propellants, and small solid rocket motors throughout storage, handling, and shipment. Reporting to the Materials & Production Planning Manager, this role owns the selection or physical design of every package we ship - selecting materials, designing cushioning and containment systems, qualifying configurations through testing, and ensuring that what leaves our facility arrives intact, safe, and compliant. The Hazardous Materials Packaging Specialist works at the intersection of engineering, operations, and logistics, partnering with production, quality, and the supply chain team to make sure protection is built into the packaging from the start - not added as an afterthought. Hazmat compliance with DOT, IATA, and DoD military packaging standards is an integral part of this role, supporting the design decisions that keep our products and our people safe.

In this role, the essential functions are:

Package Design & Development

• Design packaging systems for energetic articles, propellants, and small solid rocket motors from the ground up - including primary containment, interior cushioning and blocking, closure systems, and outer shipping containers - engineered to protect product integrity through the full distribution and storage life cycle.
• Select packaging materials - fiberboard, wood, steel, aluminum, foam, and composite constructions - based on product fragility, weight, dimensional requirements, chemical compatibility with energetic formulations, electrostatic properties, and expected environmental conditions during transit and storage.
• Use cushion curve data, fragility assessments, and drop height analysis to size and configure cushioning materials that absorb shock and vibration energy without transmitting damaging forces to the product; document the design rationale for each configuration.
• Engage with propulsion and mechanical engineers early in the product development process to understand product geometry, mass properties, and fragility before a design is finalized - translating those inputs into packaging requirements that are feasible, repeatable, and cost-effective to produce.
• Produce complete packaging design packages including appropriate engineering drawings, material specifications, Bills of Materials (BOM), assembly work instructions, and Packaging Data Sheets (PDS) that enable manufacturing and shipping personnel to consistently replicate every approved configuration.

Product Protection & Preservation

• Define required preservation methods for each packaged item - including desiccants, moisture barrier bags, vapor corrosion inhibitors (VCI), inert gas purging, and hermetic sealing - matched to the specific degradation risks of the energetic formulation, the expected storage duration, and the deployment environment.
• Coordinate with energetics chemists and materials engineers to evaluate compatibility between packaging materials and propellant or explosive formulations - identifying any risk of outgassing, chemical migration, or material interaction that could degrade product performance or reduce safety margin over shelf life.
• Investigate field returns, in-transit damage reports, and customer complaints related to packaging performance; perform root cause analysis, implement corrective actions, and redesign packaging configurations as needed to prevent recurrence.

Packaging Testing & Qualification

• As required, plan and execute qualification testing for new and revised packaging designs, such as UN performance tests (drop, stacking, vibration, leakproofness) per the UN Manual of Tests and Criteria, ASTM D4169, MIL-STD-2073-1 and MIL-STD-810.
• As needed, evaluate packaging materials for electrostatic discharge (ESD) risk in applications involving electro-explosive devices (EEDs), in accordance with the site ESD control program; separately, verify that packaging configurations satisfy applicable Hazards of Electromagnetic Radiation to Ordnance (HERO) requirements under MIL-STD-464. Ensure no inadvertent initiation risk is introduced by packaging materials or assembly processes.
• Analyze test results, identify failure modes, and drive iterative design improvements until all packaging systems meet or exceed acceptance criteria before releasing configurations to production.

Production & Supply Chain Coordination

• Work closely with the Materials & Production Planning Manager to align packaging design timelines with production schedules, ensuring that qualified packaging configurations and materials are available when products are ready to ship - without creating schedule bottlenecks.
• Train production and shipping personnel on approved packaging assembly procedures, work instructions, and inspection criteria; verify through floor observation and periodic checks that packaged products meet the approved configuration before shipment release.

Hazmat Compliance & Shipping Documentation

• Ensure all packaging designs comply with applicable hazardous materials transport regulations including DOT 49 CFR Parts 100-185, IATA Dangerous Goods Regulations (DGR), MIL-STD-2073-1, MIL-STD-129, and ATF explosives requirements; integrate compliance requirements into the design process rather than treating them as a final check.
• Define hazard labels, placards, and markings in accordance with DOT, IATA, MIL-STD-2073-1, and MIL-STD-129 requirements; maintain a current library of approved documentation templates and update them promptly when regulations change.

Basic Qualifications:

• Must be 21 years of age or older.
• Must be able to pass a pre-employment drug screening and State and Federal background checks.
• Eligible to obtain and maintain State and Federal explosives licenses.
• 3+ years of experience designing and developing industrial packaging, with demonstrated responsibility for packaging that physically protects products during shipment and storage.
• Hands-on experience selecting and sizing cushioning materials; familiarity with cushion curve data, fragility assessments, and drop height analysis as applied to packaging design.
• Working knowledge of MIL-STD-2073-1 and UN dangerous goods packaging requirements and DOT 49 CFR hazardous materials regulations; current DOT Hazmat Employee training certificate (49 CFR 172.704) or ability to obtain within 90 days of hire.
• Ability to produce clear packaging design documentation including drawings, work instructions, BOMs, and test reports; proficiency with standard engineering tools and document control practices.
• Strong attention to detail and a hands-on, problem-solving approach; comfortable working on the manufacturing floor and in restricted storage areas as well as at a desk.
• Familiarity with ITAR/EAR export control requirements as applied to defense articles.
• Ability to obtain and maintain a DoD Secret clearance.

Preferred Qualifications:

• Bachelor's degree in Mechanical Engineering, Packaging Engineering, Aerospace Engineering, or a related technical field, or an equivalent combination of education and hands-on packaging design experience.
• Experience designing packaging for Class 1 (Explosives) articles, solid rocket motors, pyrotechnic devices, or other hazardous defense materials.
• Familiarity with MIL-STD-129 and MIL-STD-810 military packaging and environmental standards, and with ESD control program requirements applied to energetic and electro-explosive devices.
• Hands-on experience with UN packaging qualification testing per the UN Manual of Tests and Criteria or ASTM D4169 distribution simulation.
• IATA Dangerous Goods Regulations (DGR) certification or Certified Packaging Professional (CPP) designation from the Institute of Packaging Professionals (IoPP).
• Prior experience in a defense manufacturing, ordnance, or aerospace environment; prior military logistics or ordnance MOS/rate is a plus.

Work Environment

Work is performed across office, manufacturing, and warehouse environments. Personal protective equipment (PPE) is required in operational areas. This role will regularly enter Explosives Safety Quantity Distance (ESQD) arcs and other restricted areas to inspect, assemble, and verify packaged items; compliance with all site explosive safety rules is mandatory at all times.

Physical Demands

• Regular standing, walking, and movement across manufacturing and warehouse areas.
• May be required to lift up to 50 pounds when handling, assembling, or testing packaging configurations.
• Sitting or standing at a desk and working on a computer for documentation and design tasks.
• Use of personal protective equipment appropriate to the work location.

Travel

This position may require up to 15% travel to packaging test laboratories, supplier facilities, and military delivery locations.

Position Type and Expected Hours of Work

This is a full-time position. This is a 9/80 Schedule with one workday off every two weeks.

The good faith base salary range for this role is $80,000 - $115,000 at the time of this posting. Where you fall within the range depends on your experience, skills, and location. This range reflects base salary only and does not include benefits or bonus/incentive. This range may be adjusted in the future.

Voyager offers a highly competitive total compensation package designed to support the well-being, growth, and success of our employees. Employees benefit from a flexible and comprehensive rewards program that supports both professional and personal well-being.

• Flexible Time Off (FTO), empowering employees to take the time they need to recharge and maintain a healthy work-life balance
• Comprehensive medical, dental, and vision coverage for employees and their families, with a significant portion of premiums covered by the company and many benefits paid at 100% for employees
• Flexible, affordable gym memberships with 12,700+ options nationwide, including 24 Hour Fitness, EoS Fitness, Crunch Fitness, Anytime Fitness, Blink Fitness, Chuze Fitness, and more! No long-term contracts and FREE on-demand workout videos before you enroll
• 401(k) retirement plan with a 50% company match on contributions up to 8%, supporting long-term financial security
• Company wellness programs that support physical and mental well-being
• Additional voluntary benefits and employee support resources
• The opportunity to work alongside a highly talented team in an innovative, mission-driven environment

Colorado pay range

$80,000-$115,000 USD