Site Operations Manager

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.

This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.

We are seeking a Site Operations Manager to own end-to-end operations of Castelion's R&D manufacturing and testing site for solid rocket motors (SRMs). This leadership role is responsible for the safe, efficient, and high-quality execution of propellant manufacturing, motor assembly, and testing activities supporting prototype, development, and early production hardware for hypersonic programs including Blackbeard. You will lead a multidisciplinary team of engineers, technicians, and operators;

drive operational excellence across manufacturing and test; and ensure the site delivers on aggressive development schedules while maintaining the highest standards of energetic materials safety, quality, and compliance. This position serves as the primary operational leader for the development site and partners closely with Propulsion Design, Manufacturing Engineering, Test Engineering, Quality, and Program Management.

• Own day-to-day operations of the development site, including propellant manufacturing (mixing, casting, curing), SRM assembly/integration, and testing (static fire, environmental, functional, and related development tests).
• Lead, mentor, and develop a high-performing team of manufacturing engineers, test engineers, technicians, and operators; foster a strong safety culture and continuous improvement mindset.
• Develop and execute site operational plans, schedules, and resource allocation to meet program milestones for R&D builds and testing campaigns.
• Drive process maturity, yield improvement, throughput, and cost efficiency while transitioning processes from R&D/prototype to more repeatable production-ready methods.
• Ensure rigorous compliance with energetic materials handling, DoD 4145.26-M, ATF regulations, ITAR, range safety, and all site-specific explosive safety and environmental standards.
• Oversee facility readiness, equipment uptime, maintenance coordination, and capital planning for mixers, casting systems, test stands, instrumentation, and support infrastructure.
• Partner with Test Engineering and Propulsion teams to plan, resource, and execute safe and effective static fire and other development tests; support post-test data reviews and anomaly resolution.
• Collaborate cross-functionally with Design, Manufacturing Engineering, Quality, Supply Chain, and Automation teams on new product introduction, process changes, and design-for-manufacturability/testability feedback.
• Lead root-cause investigations, corrective actions, and continuous improvement initiatives across manufacturing and test operations.
• Support capability expansion and knowledge transfer as processes scale to higher-rate production sites (including Project Ranger in New Mexico).

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Manufacturing Engineering, Industrial Engineering, or related technical field.
• 10+ years of progressive experience in manufacturing, operations, or test leadership within aerospace, defense, propulsion, or energetic materials environments.
• 5+ years in a supervisory or management role leading teams responsible for production, R&D manufacturing, or testing operations.
• Demonstrated experience owning or significantly contributing to solid rocket motor, propellant, or analogous high-hazard manufacturing and testing operations.
• Working knowledge of solid rocket motor manufacturing processes (propellant mixing/casting, composite case integration, assembly) and development testing (static fire, instrumentation, data acquisition).
• Familiarity with facility and equipment management for energetic materials operations, including safety systems and hazardous process controls.
• Ability to interpret engineering drawings, process specifications, test plans, and quality requirements.
• Working knowledge of ERP/MES systems, configuration management, and production control practices.

• Direct leadership experience in solid rocket motor or missile propulsion R&D manufacturing and testing environments.
• Background in fast-paced aerospace or defense organizations (startups or primes) with aggressive development timelines.
• Experience standing up or scaling new manufacturing/test capabilities or facilities.
• Prior responsibility for energetic materials safety programs, ATF compliance, or range safety interfaces.
• Familiarity with ITAR-controlled programs and classified operations.
• Experience supporting transition of processes from development site to…