About Prometheus Energetics

Position Summary

In this role, you will be responsible for bringing early-stage solid rocket motor concepts to life—from motor cases, nozzles, and igniters to specialized processing and assembly tooling. You will bridge initial product definition and shop-floor execution by developing 3D CAD models, detailed 2D engineering drawings, GD&T disclosures, and Interface Control Documents (ICDs). Working closely with Systems Engineering, Analysis, Manufacturing, Quality, and Test teams, you will ensure fast-turn SRM designs meet rigorous performance, structural/thermal margins, producibility, and explosive safety standards.

Key Responsibilities

• CAD Modeling & Technical Drawings: Lead the 3D CAD modeling and drafting of complex SRM components, including motor cases, closure assemblies, nozzles, insulation/liners, igniter housings, and secondary structural brackets using PTC Creo or Siemens NX.
• Interface Control & Documentation: Draft and maintain Interface Control Documents (ICDs), Interface Summary Sheets, and drawing tree structures for single motor prototype builds and test integration.
• Design Trade Studies: Perform design trade studies to evaluate material selection, structural joint configurations (e.g., bolted joints, composite/bonded interfaces), and manufacturability vs. weight/performance constraints.
• Tolerance & Assembly Analysis: Perform stacked tolerance analyses using ASME Y14.5 GD&T principles to ensure seamless fit-up and function across motor assemblies and test stand interfaces.

• Design for Producibility (DFM/DFA): Partner with process, tooling, and quality engineers to optimize design disclosures for rapid-turn manufacturing, energetic mixing/casting, and specialized tooling setup.
• Tooling & Ground Support Design: Assist in the design and conception of special tooling, rotation carts, casting fixtures, and static test stand interfaces to support safe, remote-operated energetic handling.
• Technical Milestone Reviews: Develop and present technical design packages for milestone reviews, including Preliminary Design Reviews (PDR), Critical Design Reviews (CDR), and internal engineering board reviews.
• Post-Fire Hardware Evaluation: Participate in post-fire hardware inspections, post-test disassembly, and telemetry/hardware correlation to drive iterative design improvements.

• MRB Engineering Support: Support Material Review Board (MRB) evaluations by evaluating discrepant hardware, performing engineering dispositions (Use-As-Is, Rework, Scrap), and determining structural/functional impacts.
• Root Cause & Anomaly Investigations: Lead or support formal Root Cause Corrective Action (RCCA) investigations for hardware defects, manufacturing escapes, and test anomalies using 5-Why and 8D methodologies.
• Failure Analysis: Utilize Failure Mode and Effects Analysis (FMEA) to identify and mitigate design-inherent failure modes early in the prototyping phase.

• Explosive & Safety Integration: Design components and tooling in compliance with site-specific explosive safety standards (DoD 4145.26-M), Electrostatic Discharge (ESD) controls, and hazardous location classifications (Class I/II, Div 1/2).
• AS9100 & Drawing Standards: Ensure compliance with AS9100 quality management systems, defense drawing release standards, and trade compliance protocols (ITAR / EAR).

Performance Management

• Rapid prototype facility milestone execution, test stand commissioning schedules, and process design-to-release compliance.
• Lead time for single rocket motor prototype iteration, build-to-test cycle speed, and milestone delivery.
• Vendor quality, delivery performance, and technical drawing compliance for specialized prototyping equipment, tooling, and test instrumentation.
• First-pass yield, prototype scrap/rework impact, and early-stage cost of poor quality mitigation.
• Root-cause investigation aging, recurrence prevention, and RCCA effectiveness during pilot builds and test firings.
• Equipment proof-load, test stand calibration, and preventive maintenance plan compliance.
• Explosive safety, ESD, and ergonomic compliance across all active processing and test assets.
• Small team capability development, technical mentorship, and rapid-response project support effectiveness.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related STEM discipline.
• Minimum of 4+ years of progressive engineering experience in mechanical/propulsion design, with direct experience in solid rocket motors, missile systems, or high-hazard energetic hardware.
• Advanced proficiency in 3D CAD modeling and drafting (PTC Creo or Siemens NX) and PDM/PLM systems (e.g., PTC Windchill).
• Strong working knowledge of ASME Y14.5 GD&T, tolerance stack-up analysis, strength of materials, and precision metal/composite fabrication methods.
• Proven experience preparing complete engineering drawing packages, assembly trees, and interface control documents for aerospace or defense systems.
• Strong verbal and written communication skills with the ability to present complex technical content to multi-disciplinary teams.
• U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

• Master of Science in Mechanical or Aerospace Engineering.
• 6+ years of experience designing solid rocket motor components (nozzles, motor cases, closures, igniters) or energetic processing/test tooling in a startup or defense prime environment.
• Experience performing basic FEA (structural/thermal) using ANSYS, Abaqus, or NASTRAN to guide initial component sizing prior to formal analysis handoff.
• Formal MRB certification with experience dispositioning complex metallic, composite, or bonded hardware.
• Hands-on experience with composite filament winding, metal forging/machining, elastomer/liner application, and energetic mixing/casting tooling.
• Active U.S. DoD Secret or Top Secret Security Clearance.

Work Environment & Physical Requirements

• Work is performed in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas subject to enhanced safety and security controls.
• Must be able to wear required personal protective equipment (PPE) and comply with site safety, explosive-safety, electrostatic discharge (ESD), and access-control requirements.
• Ability to move throughout a manufacturing site, inspect physical tooling, participate in shop-floor audits, and occasionally lift up to 25 pounds.
• Regular, reliable attendance is required. Periodic travel to vendor machine shops, secondary company facilities, or customer sites may be required during startup, tool qualification, or critical production events.

Benefits

• Medical, dental, and vision insurance
• Life and AD&D insurance; short- and long-term disability coverage
• 401(k) savings plan
• Paid time off and company holidays