Define and execute the R&D roadmap for solid propulsion subsystems, including grain design, liner chemistry (adhesion promoters, stress-relief layers), insulation architectures (elastomeric, phenolic, and composite ablative systems), and nozzle/case thermal protection, aligning laboratory choices with program ballistic targets, environmental constraints, and shelf-life objectives. Reporting directly to the Director of Engineering, this role leads a multi-disciplinary team of formulation chemists, materials engineers, and test specialists in the development, laboratory-scale testing, optimization, and pilot-scale transition of solid propulsion systems — spanning propellant formulations, bond-line liner systems, and internal thermal insulation.

R&D Manager – Solid Propulsion

LOCATION Bloomington, Indiana	REPORTS TO Director of Engineering	EMPLOYMENT Full-time
FUNCTION Engineering	TRAVEL As required	CLEARANCE Secret Clearance (or ability to obtain; US Citizenship required)

About Prometheus Energetics

Prometheus Energetics is an independent U.S.-based merchant supplier of solid rocket motors and warheads. A joint venture between Kratos Defense & Security Solutions and Rafael Advanced Defense Systems, Prometheus combines U.S. industrial speed and credibility with decades of combat-proven designs, manufacturing know-how, and technical training to deliver field-ready products at scale.

Position Summary

The R&D Manager – Solid Propulsion serves as a senior technical leader for solid rocket motor development, energetic materials formulation, and propulsion subsystem design, characterization, and process support at Prometheus Energetics. Reporting directly to the Director of Engineering, this role leads a multi-disciplinary team of formulation chemists, materials engineers, and test specialists in the development, laboratory-scale testing, optimization, and pilot-scale transition of solid propulsion systems — spanning propellant formulations, bond-line liner systems, and internal thermal insulation. The ideal candidate has deep experience with energetic materials and solid composite propellant manufacture and formulation, a strong background in rocket motor testing, and previous technical functional management experience.

Key Responsibilities

• Lead, mentor, and grow a team of formulation chemists, materials engineers, and test specialists across propellant, liner, and insulation disciplines.
• Define and execute the R&D roadmap for solid propulsion subsystems, including grain design, liner chemistry (adhesion promoters, stress-relief layers), insulation architectures (elastomeric, phenolic, and composite ablative systems), and nozzle/case thermal protection, aligning laboratory choices with program ballistic targets, environmental constraints, and shelf-life objectives.
• Own the transition of motor designs from laboratory demonstration through pilot-scale and full-rate production, establishing process windows for mixing, vacuum casting, cure, liner application, and insulation layup.
• Direct and support static fire test campaigns, data reduction, and post-fire forensics; lead failure analysis and root-cause investigations for bond-line failures, insulation debonding, and ballistic anomalies.
• Interface with program management, quality assurance, and customers on technical baselines, qualification plans, and milestone delivery.
• Drive adoption of advanced process technologies (automation, additive manufacturing, in-line process monitoring) to improve throughput, repeatability, and safety.
• Ensure compliance with DoD 4145.26-M, AS9100, Nadcap, and ITAR/EAR requirements across all R&D activities.

Required Qualifications

• Bachelor's degree in Chemistry, Chemical Engineering, Aerospace/Mechanical Engineering, Materials Science, or a related technical field (Master's or Ph.D. preferred with concentration in energetic materials, polymer science, or propulsion).
• Minimum of 8+ years of progressive experience in solid rocket motor development, energetic materials formulation, or reactive materials manufacturing within an aerospace and defense environment, including direct experience formulating and manufacturing solid composite propellants.
• Previous technical functional management experience, with a proven track record of leading, mentoring, and scaling multi-disciplinary engineering teams.
• Robust experience in rocket motor testing, including planning and executing static fire campaigns and interpreting ballistic, thermal, and structural performance data.
• In-depth knowledge of propellant chemistry and processing, including binder systems (HTPB, PBAN), oxidizers, cure kinetics, and rheological behavior.
• Working knowledge of liner and insulation materials and processes (e.g., EPDM, nitrile rubbers, phenolics, carbon-filled ablators) and bond-line integrity methodologies.
• U.S. Person as defined by ITAR (22 CFR 120–130), with the ability to obtain and maintain a U.S. Government Secret Security Clearance and required export authorizations.

Preferred Qualifications

• Experience standing up propellant formulation capabilities, mixing/casting lines, or characterization laboratories in a facility startup or defense production environment.
• Demonstrated experience delivering qualified motor systems into defense production programs.
• Familiarity with DoD 4145.26-M (DoD Contractors' Safety Manual for Ammunition and Explosives), Nadcap, AS9100, or ISO 9001 quality systems.
• Hands-on characterization experience with FTIR, DSC, TGA, DMA, and rheometry.

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, 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

EQUAL OPPORTUNITY EMPLOYER
Prometheus Energetics is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, pregnancy, genetic information, disability, protected veteran status, or any other status protected by applicable federal, state, or local law.

Powered by JazzHR