Plastics Formulation Engineer Jobs (NOW HIRING)

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.

The Propellant Chemist / Formulation Engineer serves as a core technical contributor for energetic material formulation, characterization, and process support at Prometheus Energetics. Reporting directly to the Director of Engineering, this role supports the development, laboratory-scale testing, optimization, and pilot-scale transition of solid composite propellant formulations.

Working closely across Engineering, Operations, Safety, and test teams, this engineer helps translate ballistic and mechanical requirements into safe, robust, and reproducible energetic formulations. The position participates in the end-to-end formulation lifecycle—including raw material evaluation, binder system optimization, mixing parameters definition, and hands-on laboratory support.

Key Responsibilities

Formulation Design, Chemistry & Characterization

• Assist in executing propellant formulation strategies, aligning laboratory choices with program ballistic targets, environmental constraints, and shelf-life objectives.
• Support the design, preparation, and optimization of solid composite propellant formulations, including binder matrices (e.g., HTPB), oxidizers (e.g., AP), metal fuels (e.g., Aluminum), plasticizers, bonding agents, and cure catalysts.
• Conduct laboratory-scale mixing, casting, and sample preparation under strict safety protocols.
• Perform hands-on physical and chemical characterization testing using instrumentation such as FTIR, DSC, TGA, DMA, and rheology to evaluate thermal stability, cure kinetics, and mechanical properties.
• Evaluate raw material lots and support supply chain risk assessments to ensure component pedigree and consistency.

Process Development & Manufacturing Support

• Partner with Process Engineering and Operations to transition lab-scale recipes into pilot and production-scale mixing and casting processes.
• Help establish critical process parameters (CPPs) for ingredient preparation, vacuum mixing, casting, and cure cycles to minimize batch variability, voids, and defects.
• Provide floor-level engineering support to Propellant Operations, helping troubleshoot active mixing or casting issues, analyze anomalies, and support root-cause corrective action (RCCA).
• Support Design for Manufacturability (DFM) and process improvement efforts utilizing statistical process control (SPC) and Design of Experiments (DOE).

Technical Documentation, Compliance & Safety

• Author and maintain technical documentation, including laboratory notebooks, Formulation Control Documents (FCDs), standard operating procedures (SOPs), and test reports.
• Coordinate directly with EHS and Energetics Safety teams to ensure all handling, blending, and testing activities comply with DoD 4145.26-M standards, electrostatic discharge (ESD) controls, and hazardous material protocols.
• Ensure strict adherence to ITAR and export control regulations regarding energetic material data.

Required Qualifications

• Bachelor's degree in Chemistry, Chemical Engineering, Materials Science/Engineering, or a related technical discipline.
• Minimum of 4 years of progressive hands-on experience in energetic materials formulation, propellant chemistry, or reactive materials manufacturing within an aerospace and defense environment.
• Solid understanding of solid composite propellant ingredients, binder systems (e.g., HTPB), curing chemistry, and energetic material thermodynamics.
• Demonstrated proficiency with materials characterization and laboratory instrumentation (e.g., FTIR, DSC, TGA, rheometers).
• Familiarity with pilot-scale mixing, vacuum casting processes, and manufacturing floor support.
• U.S. Citizen with the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

• Master's or Ph.D. in Chemistry, Chemical Engineering, Aerospace Engineering, or a related field, with a concentration in energetic materials, polymer chemistry, or reactive materials.
• Direct experience formulating and manufacturing propellants for solid rocket motors, warheads, gas generators, or ammunition systems.
• Experience standing up propellant formulation capabilities, mixing/casting lines, or characterization laboratories in a facility startup or defense production environment.
• Familiarity with DoD 4145.26-M (DoD Contractors' Safety Manual for Ammunition and Explosives), Nadcap, AS9100, or ISO 9001 quality systems.
• Demonstrated effectiveness as a principal investigator on internal R&D efforts, with publications or presentations in relevant defense-industry journals or conferences.
• Experience with statistical process control (SPC), design of experiments (DOE), and process FMEA methodologies.
• Active US Secret or higher 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, 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