Energetics Safety Manager

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.

The Energetics Safety Manager leads Castelion’s enterprise Energetics Safety Program and is responsible for establishing the policies, standards, procedures, training, and risk management framework needed to support the safe design, manufacture, storage, transportation, testing, and disposal of energetic materials.

As part of the Environmental, Health & Safety organization, this role provides independent energetics safety oversight and partners with Engineering, Manufacturing, Test, Facilities, Security, Supply Chain, Quality, and Program Management to integrate safety throughout the product and operational lifecycle. The position supports and coordinates energetics safety across all Castelion locations conducting energetic operations.

Energetics Safety Program

• Lead the development, implementation, and continuous improvement of Castelion’s Energetics Safety Program.
• Establish and maintain company-wide policies, standards, procedures, specifications, and training for energetic operations.
• Promote consistent practices across manufacturing, ground test, flight test, storage, transportation, and disposal activities.
• Incorporate lessons learned, regulatory changes, and industry practices into program improvements and the broader EHS Management System.
• Develop and maintain processes for identifying, evaluating, documenting, and managing risks associated with energetic materials and operations.
• Lead or facilitate qualitative and quantitative hazard analyses, including PHAs, HAZOPs, FMEAs, What-If analyses, QRAs, and Quantity-Distance evaluations, as appropriate.
• Support facility siting, hazard classification, blast and fragmentation assessments, consequence analysis, and operational readiness activities.
• Partner with Engineering and Operations to develop risk reduction strategies using sound engineering principles and the hierarchy of controls.
• Ensure residual risks, assumptions, and required safeguards are clearly documented and elevated through the appropriate risk acceptance process.

Safety Integration & Operational Support

• Lead the integration of energetics safety across engineering, manufacturing, and test operations without assuming ownership of technical design or operational execution.
• Establish standardized approaches for safely conducting energetic manufacturing, ground test, and flight test activities.
• Coordinate energetics safety support for major test campaigns and other high-consequence operations to ensure personnel, facilities, equipment, and safeguards are aligned.
• Support operations conducted at external ranges and ensure alignment with applicable customer and range safety requirements.
• Represent EHS as a key stakeholder throughout the engineering and operational lifecycle.
• Participate in design reviews, manufacturing and production readiness reviews, operational readiness reviews, and ground and flight test readiness reviews.
• Evaluate whether energetics hazards, risk controls, and verification requirements are appropriately identified and addressed before execution.
• Provide independent recommendations regarding energetics risk, operational safeguards, and residual risk acceptance while preserving Engineering’s authority over technical design decisions.

Regulatory Compliance & Governance

• Lead enterprise compliance with applicable energetics and explosives safety requirements.
• Interpret and implement applicable DoD explosives safety standards, DoD 4145, ATF, OSHA, DOT, NFPA, and federal, state, local, customer, and range-specific requirements.
• Develop compliance strategies, maintain required documentation, and support regulatory inspections, customer audits, government reviews, and explosives safety…