Sr. Materials & Process Engineer, Energetic MaterialsJob Title: Sr. Materials & Process Engineer, Polymer Materials
Reports To: Director of Materials Engineering
Location: Torrance, CA / Rio Rancho, NM
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.
Key Outcomes for 2026 - 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.
Key Responsibilities - Lead characterization of propellant and related polymeric material systems using mechanical testing, DMA, rheometry, DSC/TGA, microscopy, and other relevant techniques.
- Develop test methods to understand material behavior across relevant temperatures, strain rates, aging conditions, and operational environments.
- Develop and execute material qualification and acceptance testing programs for raw materials and cast propellant.
- Lead failure analysis and root-cause investigations related to material performance, processing, and manufacturing defects.
- Develop and maintain material specifications, process controls, test plans, and acceptance criteria.
- Partner with Propulsion and Manufacturing Engineering to translate characterization results into material selection, processing requirements, and design inputs.
- Support manufacturing scale-up by identifying relationships between processing conditions, material structure, and resulting properties and performance.
- Ensure material testing and qualification activities comply with applicable material, handling, and safety requirements.
Basic Qualifications - Bachelor's degree in materials science/engineering, chemistry or a related discipline.
- 5+ years of experience working with polymer characterization, preferably within the aerospace industry.
- Prior experience with propellant characterization techniques including mechanical testing, impact, static, burn-rate, and impulse testing.
- Excellent written and verbal communication skills.
- Must be authorized to work in the U.S. and comply with ITAR eligibility requirements.
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.
