Sr. Materials & Process Engineer, Energetic Materials Torrance, CA, Rio Rancho, NM Manufacturing

• Manufacturing

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, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.

Sr. Materials & Process Engineer, Energetic Materials

Job 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…