Senior Manufacturing Engineer (Propellant)

Company Overview:

VALT Enterprizes, Inc. is revolutionizing aerospace with cutting-edge hypersonic research and development to pioneer America’s first-of-its-kind hypersonic launch system, combining rocket and air-breathing propulsion to empower our nation’s warfighters with the tools they need to safeguard our country. We envision a world where access to space is no longer a privilege for the few but an opportunity for all. Our team is driven by data, fueled by passion, and united by a shared commitment to innovation and resilience. Challenges are embraced head-on in a culture that values creativity, determination, and collaboration. Join us in shaping the future of aerospace and making history – together.

Position Overview:

We are seeking an experienced Senior Manufacturing Engineer to lead the development, implementation, optimization, and validation of manufacturing processes for solid propellant production in advanced aerospace and defense applications. In this role, you will collaborate with propulsion engineering, manufacturing, quality, safety, and operations teams to establish and improve propellant mixing, casting, curing, and handling processes, evaluate manufacturing equipment and automation technologies, and ensure solid propellant production meets established quality, performance, and safety requirements.

Operating with a high degree of technical independence, you will address complex manufacturing challenges, develop and refine process controls, investigate production deviations, and implement continuous improvement initiatives while maintaining strict adherence to applicable regulatory and explosives safety standards. You will also provide technical guidance and hands-on support to manufacturing technicians while advancing VALT's solid propellant manufacturing capabilities.

Key Responsibilities:

• Develop, document, implement, and continuously improve manufacturing processes, process parameters, work instructions, and control plans supporting solid propellant production
• Establish and optimize manufacturing methods for propellant mixing, casting, curing, and handling to improve process consistency, repeatability, efficiency, and product quality
• Collaborate with propulsion engineers to ensure manufacturing processes align with solid propellant design specifications, performance requirements, and production objectives
• Research, evaluate, and recommend manufacturing equipment, tooling, and technologies supporting propellant mixing, casting, curing, and related production operations
• Develop and implement equipment qualification and process validation methods to ensure manufacturing equipment and processes meet established technical, quality, and safety requirements
• Collaborate with propulsion engineering and operations teams to introduce and improve manufacturing automation while maintaining strict process controls and explosives safety standards
• Ensure manufacturing processes comply with applicable Department of Defense (DoD) explosives safety requirements, including DoD 4145.26-M, Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF) regulations, International Traffic in Arms Regulations (ITAR), and site-specific explosives safety standards
• Work with propulsion and quality engineering teams to establish and implement solid propellant acceptance criteria, inspection requirements, and manufacturing quality controls
• Investigate manufacturing process deviations, defects, and quality issues through root cause analysis (RCA) and implement corrective and preventive actions to improve process reliability and prevent recurrence
• Analyze manufacturing data, process performance, and production trends to identify opportunities for process optimization, defect reduction, and continuous improvement
• Collaborate with engineering, safety, quality, and operations teams to identify manufacturing hazards, evaluate process risks, and implement appropriate safety controls and risk mitigation measures
• Provide hands-on technical guidance, troubleshooting assistance, and training to manufacturing technicians supporting propellant production, equipment operation, and process development activities
• Prepare and maintain manufacturing documentation, technical reports, process records, and validation results to support process control, traceability, and continuous improvement

Required Qualifications:

• Bachelor's degree in manufacturing engineering, mechanical engineering, chemical engineering, aerospace engineering, or a related engineering discipline from an ABET-accredited institution
• 6+ years of manufacturing engineering experience supporting process development, production operations, equipment implementation, or manufacturing process optimization
• Strong understanding of manufacturing engineering principles, process controls, production methods, and continuous improvement practices
• Experience developing, documenting, implementing, and optimizing manufacturing processes, work instructions, and production control plans
• Experience evaluating manufacturing equipment, establishing process parameters, and supporting equipment qualification or process validation activities
• Knowledge of manufacturing quality principles, inspection requirements, root cause analysis, and corrective and preventive action processes
• Experience troubleshooting manufacturing process deviations, equipment issues, and production challenges to develop and implement effective technical solutions
• Ability to interpret engineering drawings, technical specifications, process documentation, and manufacturing requirements
• Strong analytical and problem-solving skills with the ability to evaluate complex manufacturing challenges and implement practical solutions
• Strong technical documentation and communication skills with the ability to prepare manufacturing procedures, technical reports, and process validation documentation while collaborating across multidisciplinary teams
• Ability to manage multiple technical priorities in a fast-paced research, development, and manufacturing environment
• Experience providing technical guidance and support to manufacturing technicians or junior engineering personnel
• U.S. citizen with the ability to obtain and maintain a U.S. government security clearance

Preferred Qualifications:

• Master's degree in manufacturing engineering, mechanical engineering, chemical engineering, aerospace engineering, or a related engineering discipline
• Experience supporting solid rocket propellant manufacturing, energetic materials processing, explosives manufacturing, or related aerospace and defense production operations
• Familiarity with solid propellant mixing, casting, curing, handling, and associated manufacturing equipment and process controls
• Knowledge of DoD 4145.26-M, ATF regulations, ITAR, and applicable explosives safety requirements
• Experience researching, selecting, commissioning, or validating specialized manufacturing equipment and automation technologies
• Experience developing and implementing automated manufacturing processes, process monitoring systems, or advanced production controls
• Familiarity with AS9100 quality management requirements and aerospace or defense manufacturing standards
• Experience supporting the transition of manufacturing processes from research and development (R&D) to repeatable production operations
• Experience leading manufacturing process improvement initiatives or providing technical leadership within multidisciplinary engineering and production teams