Propulsion Engineer (Solid Rocket Motor Ballistics)We are seeking a solid rocket motor ballistician to own the performance predictions of our motors. This position is central to our ability to deliver at speed and scale, with a strong emphasis on driving technically sound designs that meet aggressive schedule, affordability, and production goals.
Responsibilities- Design and develop rocket motor systems, including grain geometry, case structures, insulation, and nozzle assemblies.
- Lead the architecture and detailed design of propulsion hardware to meet performance, structural, and thermal requirements
- Perform internal ballistics, thermal, and structural analyses to ensure motor performance and reliability under extreme operating conditions
- Advance the internal Castelion capabilities for analysis predictions and correlation to tests for solid rocket motor propellant as well as ignition systems (BKNO3)
- Work closely with structures, thermal, GNC, and manufacturing teams to ensure seamless integration of propulsion systems with the vehicle
- Support propellant selection, processing, and characterization in collaboration with materials and manufacturing teams
- Plan and execute static fire tests and development test campaigns, including instrumentation, data collection, and post-test analysis
- Conduct failure analysis and root cause investigations, driving design improvements and risk reduction
- Define and execute qualification and flight test plans, translating results into system-level improvements
- Optimize designs for performance, mass, manufacturability, and operational reliability
- Mentor junior engineers and contribute to best practices in propulsion system design and testing
- Partner closely with program leadership to make technical trades aligned with mission success
Basic Qualifications- Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, or related field
- 2+ years of experience in rocket propulsion design, analysis, and testing for aerospace or defense applications
- Strong background in solid rocket motor design, including internal ballistics, grain design, ignitors, and nozzle performance
- Experience with propulsion testing, including static fire test setup, instrumentation, and data analysis
- Familiarity with structural and thermal design considerations for high-temperature, high-pressure systems
- Proficiency in analysis and modeling tools (e.g., MATLAB, SPP, or equivalent)
- Experience with hardware build, integration, and troubleshooting in a lab or test environment
- Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high test cadence environment
Preferred Skills and Experience- Experience with preliminary / conceptual design from performance requirements for solid rocket motor grains
- Experience with pyrotechnic and pyrogenic ignition systems and characterizing ignitor performance.
- Experience with grain and nozzle optimization for tactical SRM systems.
- Experience correlating analytical models with physical test data.
- Aerospace, hypersonic, launch vehicle, spacecraft, or other high-performance flight hardware experience.
- Experience establishing engineering standards or methodologies.
- Demonstrated ability to mentor and develop engineers technically.
- Experience working with composites, coatings, finishes, and advanced manufacturing processes.
Additional Requirements- Willing and able to work extended hours and/or weekends with minimal notification to meet critical deadlines leading up to major milestones.
- Able to travel up to 30% on an ongoing basis
Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.
Other Duties Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.
Additional Eligibility Requirements This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.
