Senior Materials & Process Engineer, Rocket Motor Systems (Polymeric Ablatives

Senior Materials & Process Engineer, Rocket Motor Systems (Polymeric Ablatives)

This foundational role will establish the M&P infrastructure that enables RMS to scale from prototype development to high-rate production. You'll lead the development, documentation, and standardization of material specifications, process specifications, acceptance test procedures, and design allowables across multiple concurrent programs—transforming tribal knowledge and informal work instructions into robust, configuration-controlled engineering documentation. The ideal candidate combines deep technical expertise in aerospace materials with strong documentation skills and the ability to drive standardization across a fast-moving organization.

If you thrive in environments where you can build engineering infrastructure from the ground up while also solving challenging technical problems, we want to hear from you. This role is based in Costa Mesa, CA with up to 50% travel to RMS sites in MS, NC, AL, etc.

What You'll Do

• Develop and maintain Material Specifications for raw materials, components, and assemblies containing polymeric constituents across all RMS systems including propellants, cases (metal and composite), ablatives, insulators, adhesives, coatings, and nozzle materials
• Create Process Specifications for manufacturing operations including propellant processing, ablative component manufacturing, insulation/liner bonding and surface preparation, heat treatment, coating application, and final assembly processes
• Develop Standard Acceptance Test Procedures and NDI technique sheets for incoming materials, in-process inspection, and finished hardware (FTIR, Raman, X-ray, CT scan, ultrasonic, radiography)
• Review and standardize existing work instructions into formal, configuration-controlled specifications with clearly defined process windows and acceptance criteria
• Serve as subject matter expert for polymeric materials selection, processing, and qualification across solid rocket motor systems including propellants, cases, thermal protection systems (elastomeric, rubber and composite insulation/liners), nozzles, igniters, and other energetic components
• Lead materials characterization programs including mechanical testing, thermal analysis, rheology, cure kinetics, and ablation performance evaluation; develop design allowables per industry standards (CMH-17, JANNAF)
• Provide materials and process expertise to Design and Manufacturing teams; review drawings and manufacturing plans, support design reviews, and troubleshoot production issues
• Drive material and process qualifications from development through production readiness; manage supplier technical relationships and qualification activities
• Lead failure investigations and root cause analyses for material-related anomalies; participate in MRBs, FRBs, ERBs, and PCBs
• Interface with engineering, manufacturing, quality, and program teams to translate mission requirements into robust material and process solutions
• Drive cost reduction and cycle time improvement initiatives to enable high-rate production
• Mentor junior engineers and prepare technical documentation including specifications, test reports, and presentations

Required Qualifications

• Bachelor's degree in Materials Science, Chemical Engineering, Mechanical Engineering, Aerospace Engineering, or related field
• 5+ years of materials and process engineering experience in aerospace, propulsion, or defense applications
• Proven experience developing material specifications and process specifications for production programs
• Strong technical background in multiple areas such as:
• High-temperature coatings, adhesives, insulation, liners, and ablatives
• Thermal protection system (TPS) components
• Propellant materials and processing
• Adhesive bonding and surface preparation
• Experience with material characterization, testing, and documentation
• Strong technical writing skills and attention to detail
• Experience troubleshooting manufacturing processes and leading root cause investigations
• Ability to manage multiple priorities independently in a fast-paced environment
• Ability to obtain and hold a U.S. Top Secret security clearance

Preferred Qualifications

• Dir…