Senior Development Manufacturing Engineer

The future of aerospace and defense starts here.

Ursa Major was founded to revolutionize how America and its allies access and apply high-performance propulsion, from hypersonics to solid rocket motors, satellite maneuvering and launch. We design and deliver propulsion and defense systems that solve the most urgent and critical national security demands.

Ursa Major is developing cutting‑edge propulsion systems and is seeking an innovative and hands‑on Manufacturing Development Engineer. This role is pivotal in bridging the gap between design and production by creating, implementing, and optimizing the manufacturing processes for solid rocket motors (SRMs). The engineer in this role will be the designated Process Owner for a critical section of the SRM build process.

They will be responsible for the entire development lifecycle of their assigned processes, from initial concept and sourcing to machine design, fabrication, and final deployment on the production floor. This individual will serve as the primary Subject Matter Expert (SME) for their processes, actively participating in motor builds to ensure processes are robust, repeatable, and capable.

We are looking for an engineer with a strong background in capital equipment, automation, and process design, ideally with experience in composite winding, web handling, or energetics processing.

• Process Ownership & Development:
  • Take complete ownership of a designated manufacturing work cell or process (e.g., propellant mixing, case winding, insulation, or finishing).
  • Design, develop, and validate new manufacturing processes and equipment to meet design specifications, safety standards, and production rate requirements.
  • Create detailed equipment specifications, statements of work (SOW), and test plans for new machinery.
• Sourcing & Machine Design:
  • Lead the sourcing and procurement of complex capital equipment. This includes identifying and evaluating external machine builders and automation suppliers.
  • Partner with vendors or lead internal design efforts for custom manufacturing machines, tooling, and fixtures.
  • Manage projects from procurement through installation, conducting site acceptance (SAT) and factory acceptance (FAT) testing.
• Hands‑on Implementation & SME Support:
  • Act as the lead Subject Matter Expert (SME) for your assigned processes.
  • Work hands‑on with technicians and other engineers on the production floor to build development and flight hardware, providing real‑time support and process refinement.
  • Develop and qualify processes, establishing critical process parameters and controls.
  • Author and maintain comprehensive documentation, including Standard Operating Procedures (SOPs), work instructions, and maintenance requirements.
• Continuous Improvement:
  • Analyze build data, non‑conformances, and operator feedback to identify root causes and implement robust corrective actions.
  • Drive continuous improvement (Lean, 6‑Sigma) initiatives to improve safety, quality, efficiency, and cost for your process area.
  • Collaborate closely with Design Engineering (DFM/A) to ensure new motor designs are optimized for manufacturability.

• Education: Bachelor of Science (B.S.) in Manufacturing Engineering, Mechanical Engineering, Aerospace Engineering, Chemical Engineering, or a related field.
• Experience:
  • Minimum of 4 years of experience in a manufacturing engineering role, developing and deploying new production processes and equipment.
  • Proven experience leading capital equipment projects, including specification development, sourcing, and installation/commissioning.
  • Demonstrated ability to serve as a hands‑on SME, working directly on the production floor.
• Skills:
  • Strong proficiency in 3D CAD software (e.g., Solid Works, Siemens NX, CATIA) for tooling and fixture design.
  • Excellent project management skills.
  • Strong understanding of GD&T (Geometric Dimensioning and Tolerancing) and blueprint interpretation.
• Citizenship: Must be a U.S. Citizen due to the nature of the work and government contracts.
• Security Clearance: Must be able to obtain and maintain a U.S. Government Security Clearance.

• Education: Master of Science (M.S.) in…