Project Engineer at PROMETHEUS ENERGETICS, LLC – Bloomington | Jobyssey

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

Prometheus Energetics is seeking an experienced Project Engineer to lead a small team in setting up and operating a rapid prototyping and test facility in Bloomington, Indiana, dedicated to fabricating and testing single solid rocket motors (SRMs).

In this high-impact role, you will lead a nimble engineering team responsible for bringing a greenfield energetic lab, build facility, and test infrastructure online. You will bridge early-stage motor design and rapid shop-floor execution—overseeing everything from facility setup, specialized tooling, and equipment commissioning to energetic mixing, casting, motor assembly, and static test execution. Working closely with Engineering, Operations, Quality, EHS, and technology-transfer partners, you will ensure fast-turn prototype builds and static firings meet all technical, performance, and high-hazard safety requirements.

Key Responsibilities

Greenfield Facility Setup, Equipment & Test Integration

Lead technical execution for the layout, tooling integration, and installation of energetic processing and test equipment (mixers, casting chambers, rotation carts, remote-handling systems, and static test stands) for single rocket motor builds.
Establish, prove out, and sustain rapid-turn manufacturing processes, operational routers, tooling sheets, and detailed Standard Work Instructions (SWIs) for propellant handling, motor assembly, casting/curing, and static test prep.
Define capital equipment and test instrumentation specifications, evaluate vendor proposals, and manage full-lifecycle acquisition, site acceptance testing (SAT), and equipment commissioning prior to active energetic processing and testing.

Team Leadership & Rapid Execution

Directly lead a small, agile team of tooling, process, and test engineers through initial facility buildout, process qualification, and rapid motor fabrication/test cycles.
Drive project schedules, milestone deliverables, technical risk management, and budget allocation for facility capital equipment, prototype tooling, and test instrumentation.
Serve as the primary technical interface with prototype lab chemists, test technicians, and EHS teams to establish safe operational workflows, shop-floor troubleshooting guidelines, and rapid-iteration feedback loops between motor builds and test firings.

Non-Conformance, MRB & Process Validation

Act as a voting member on the Material Review Board (MRB) to evaluate single-motor prototype non-conformances, perform engineering dispositions, and implement containment protocols.
Lead formal Root Cause Corrective Action (RCCA) investigations for build anomalies, test deviations, process escapes, and tooling wear using 5-Why, Fishbone, and 8D methodologies.
Apply Lean/Six Sigma practices, Process Failure Mode and Effects Analysis (PFMEA), and mistake-proofing (poka-yoke) controls early in the prototyping and testing phase to simplify future transition into high-rate production.

Explosive Safety, ESD & Regulatory Compliance

Partner with Environmental Health & Safety (EHS) and Energetics Safety teams to strictly enforce site-specific explosive safety standards (DoD 4145.26-M), Electrostatic Discharge (ESD) controls, NFPA 495/652, and OSHA Process Safety Management (PSM) guidelines across build and test operations.
Establish site classification standards, quantity-distance (Q-D) criteria, grounding/bonding requirements, and blast mitigation/suppression controls for rapid prototyping and static testing.
Ensure full compliance with AS9100 quality standards, federal ammunition and explosives regulations, and trade compliance protocols (ITAR / EAR).

Performance Management

Establish actionable dashboards, review tooling performance with engineering and operational leadership, and hold owners accountable for recovery and improvement plans. Measures may include:

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, Chemical Engineering, or a related technical discipline. Demonstrated work history may substitute for a degree.
Minimum of 6+ years of progressive engineering experience in solid rocket propulsion, pyrotechnics, or hazardous energetic materials processing, including experience leading small technical teams or project workflows.
Proficiency in 3D CAD software (e.g., PTC Creo, Siemens NX, SolidWorks) and Product Data Management (PDM/PLM) systems (e.g., Windchill).
Solid understanding of Geometric Dimensioning and Tolerancing (GD&T per ASME Y14.5), structural strength of materials, and precision metal/composite fabrication methods.
Proven experience generating assembly routers, process flow diagrams, PFMEAs, and detailed work instructions for complex solid rocket motor hardware.
Deep knowledge of DoD energetics safety standards (DoD 4145.26-M), Process Safety Management (PSM), and hazardous location classifications (Class I/II, Div 1/2).
Excellent written, verbal, analytical, and executive communication skills.
U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

Master of Science in Mechanical Engineering, Aerospace Engineering, Chemical Engineering, or Engineering Management.
Minimum of 10+ years of progressive engineering experience in solid rocket propulsion, pyrotechnics, or hazardous energetic materials processing, including experience leading small technical teams or project workflows.
Direct experience standing up rapid-prototyping, pilot manufacturing, or ground-testing facilities for solid rocket motors in a defense startup or expansion environment.
Hands-on familiarity with energetic mixing/casting equipment, remote-operated tooling/robotics, static test stands, thrust-termination systems, and high-speed data acquisition (DAQ) equipment.
Background in developing standard operating procedures (SOPs), hazard analyses (PHA/HAZOP), static test safety protocols, and Explosive Facility Safety Site Plans.
ASQ certifications (CQE, CQA), formal GD&T certification, or Six Sigma Green/Black Belt credentials.
Active U.S. Secret Security Clearance or higher.

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

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