Lead Manufacturing Engineer - Motors

Castelion is bringing a new approach to defense development and production: one that focuses on short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production e designing, building, and testing next generation long range strike weapons systems to give America and its Allies a definitive edge and deter future conflicts.

Castelion is seeking a Lead Manufacturing Engineer to own all aspects of solid rocket motor production. In this role, you will lead a cross-functional team responsible for the safe, repeatable, and rate-capable manufacture of solid propellant motors, from propellant mixing through final acceptance. You will drive aggressive cost, quality, schedule, and safety targets in an energetics manufacturing environment while scaling production for mission-critical programs.

Lead a team of manufacturing engineers in the daily execution of solid rocket motor production, including propellant mixing, casting, case bonding, and proof/acceptance testing. Ensure on-time delivery of flight hardware while maintaining zero safety incidents and full compliance with DoD regulations.

Own the entire solid motor manufacturing value stream. Develop, qualify, and continuously improve processes, tooling, and facilities to increase throughput, reduce labor hours, and achieve first-pass yield targets. Implement automation, digital thread/MES, and advanced inspection techniques to support rapid production scaling.

Serve as the primary technical interface to Design Engineering, Program Management, Quality, EHS, and the customer on producibility, non-conformances, and anomaly resolution. Lead root-cause and drive robust corrective actions for defects or process escapes.

Lead manufacturing readiness for new solid motor designs, including process development, PFMEA, control plans, and qualification builds. Plan and execute capital projects for the installation of mixers, casting facilities, and automated insulation/liner application.

Enforce strict adherence to energetic materials safety standards (NFPA 495, DOD 4145.26M). Author and maintain explosive safety submissions, hazard analyses, and operating procedures. Champion a strong safety culture across the team.

Mentor junior engineers and technicians, conduct performance reviews, and build succession plans. Foster a culture of ownership, urgency, and technical excellence.

• Bachelors degree in Mechanical, Aerospace, Chemical, or Manufacturing Engineering.
• Minimum of 7 years of hands-on experience in an aerospace manufacturing environment or equivalent.
• At least 3 years in formal leadership.

• Proven track record leading production of solid rock motors from development through sustained rate production.
• Deep expertise in propellant formulation, vacuum casting, case-bonded grain design, liner/insulator systems, and non-destructive evaluation of energetic articles.
• Demonstrated success scaling hazardous processes while reducing cost per pound and labor hours per motor.
• Prior work on orbital launch vehicles, strategic systems, missile defense, or hypersonic programs.
• Aptitude for mentoring teams and influencing cross-functional stakeholders in a fast-paced, resource-constrained startup environment.

• Bias to Action and Creative Problem Solving
  . Desire and experience questioning assumptions in ways that lead to break through ideas that are ultimately implemented.…