Propulsion Engineer III

Propulsion Engineer III

Karman Space & Defense is a leader in the rapid design, development, and production of critical, next-generation system solutions that align with the U.S. Department of War and its allies’ core mission priorities, and meet the accelerating demand for access to space. Building on nearly 50 years of success, we deliver Payload & Protection Systems, Aero/Hydrodynamic Interstage Systems, and Propulsion & Launch Systems to more than 80 prime contractors supporting over 130 space and defense programs.

This role is part of our Tactical Missiles and Integrated Defense Systems business, which designs and develops integrated missile and defense systems that support critical missions across air, land, and sea. We combine comprehensive analysis, engineering, and program execution capabilities to deliver mission-tailored solutions that reduce lead times, lower costs, and simplify complex multi-vendor supply chains. Backed by decades of flight-proven and fielded performance, we design and build mission-critical technologies including launch systems, propulsion, payload integration solutions, UAV components, missile subsystems, and Safe & Arm systems.

In this role, you will lead solid rocket motor propulsion development, driving system-level ballistic modeling, component design, and test evaluation for advanced aerospace and defense programs. You will develop conceptual and detailed designs, verify analyses, support manufacturing and static fire testing, and collaborate across engineering teams to deliver mission-ready propulsion solutions that meet stringent performance and reliability requirements.

Responsibilities

• Supports solid rocket propulsion system design across grain geometry, case design, insulation, inhibitors, igniters, and nozzles.
• Conceptualizes, designs, and develops propulsion devices and systems based on customer requirements and engineering standards.
• Performs full ballistic modeling, including propellant selection, propellant sizing, nozzle sizing, insulation and inhibitor definition, and overall performance analysis.
• Performs or supports thermal, ablation, and erosion analyses when applicable.
• Creates 2‑D layouts and 3‑D solid models to define propulsion concepts and configurations.
• Verifies calculations, ballistic models, and analysis work completed by peers and junior engineers.
• Documents performance requirements, test plans, test procedures, test reports, and compliance evidence.
• Reviews propulsion designs for cost, manufacturability, and quality considerations.
• Creates engineering drawings, bills of materials, manufacturing requirements, and inspection specifications.
• Supports manufacturing, assembly, quality assurance, testing, and deployment throughout the propulsion development lifecycle.
• Provides technical support to internal teams, external customers, and business development activities.
• Supports bench and field testing, including static fire test setup and instrumentation selection.
• Evaluates static fire test data, including acoustic stability, delivered impulse, pressure, and thrust behavior.
• Mentors junior engineers and provides technical guidance in propulsion system development.

Required Qualifications

• Bachelor’s degree in mechanical engineering, aerospace engineering, physics, or a related field; or equivalent relevant experience.
• Typically 4–10 years of aerospace or defense engineering experience.
• Strong understanding of propulsion systems and internal ballistics modeling.
• Proven experience developing propulsion internal ballistic models, preferably for solid rocket motors.
• Knowledge of military and commercial design specifications.
• A current U.S. Department of Defense (DoD) Secret security clearance or the ability to obtain and maintain one.

Preferred Qualifications

• Master’s degree or advanced degree in mechanical engineering, aerospace engineering, physics, or a related field.
• Experience with thermal, ablation, or erosion analysis.
• Experience with acoustic stability analysis.
• Experience with igniter sizing.
• Knowledge of CAD/CAE tools relevant to mechanical systems design.
• Familiarity with ASME Y14.5 and Geometric Dimensioning and Tolerancing (GD\&T).
• Casting tooling experience.

Benefits

• Medical, dental, and vision insurance
• 401(k) with company match
• Paid time off
• Health Savings Account (HSA) with company contribution
• Flexible Spending Accounts (FSA)
• Company‑paid life and AD\&D insurance
• Short‑ and long‑term disability coverage
• Tuition reimbursement

Karman Space and Defense is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, age, disability, genetic information, protected veteran status, or any other status protected by applicable law.