Senior Structural Analysis Engineer Jobs in Columbus, IN

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.

Prometheus Energetics is seeking an experienced Ballistician & Igniter Design Engineer / Senior Ballistician to serve as a primary technical authority for interior ballistics modeling, propellant grain geometry design, and igniter system architecture for Solid Rocket Motors (SRMs). Reporting directly to the Director of Engineering, this role owns the internal ballistic lifecycle—from initial conceptual sizing, burn rate tailoring, and ignition transient modeling through static fire correlation, qualification, and high-rate production support.

Solid Rocket Motor performance relies on precise pressure-time profiles, energetic gas generation, and reliable ignition sequences under extreme environmental conditions. The ideal candidate brings 4 to 10 years of hands‑on propulsion experience in interior ballistics analysis, 2D/3D grain geometry optimization, pyrogen/BKNO3 igniter hardware design, and propellant‑ballistic performance tailoring.

• Lead interior ballistics analysis and performance prediction for solid rocket motor programs, developing 1D, 2D, and 3D pressure-time, thrust-time, and mass flow rate profiles across all operational temperature bounds.
• Design and optimize 3D propellant grain geometries (e.g., star, finocyl, slotted tube, wagon wheel, end-burning) to meet tight volumetric loading, total impulse, thrust profile, and center-of-gravity constraints.
• Perform thermochemical equilibrium calculations (e.g., NASA CEA) to evaluate propellant formulations, theoretical specific impulse, characteristic velocity, gas composition, and two-phase flow losses.
• Evaluate burn rates, pressure exponents, temperature sensitivity coefficients, erosive burning phenomena, and nozzle throat erosion behavior.
• Collaborate with propellant chemists and processing teams to specify burn rate targets, burn rate modifiers, and lot-to-lot ballistic acceptance criteria.

• Own the end-to-end design, sizing, and qualification of SRM ignition systems, including pyrogen igniters, pyrotechnic canisters, initiator interfaces, and BKNO3/pellet charges.
• Model ignition transients, flame front propagation, pyrogen gas flow, mass discharge rates, and pressure rise rates to ensure smooth, hangfire-free motor startup without over‑pressurization.
• Design igniter structural housings, closure caps, nozzle orifices, weather seals, and mechanical interfaces into motor forward domes or polar bosses.
• Oversee initiator/squib selection, safe-and-arm (S&A) device interfaces, electrical harness integration, and ESD/RF safety compliance for ordnance hardware.
• Lead subscale igniter bomb testing, closed‑bomb testing, and standalone igniter firing campaigns to characterize pyrogen ballistics prior to full‑scale motor integration.

• Plan, analyze, and reduce data from strand burner tests, subscale motor firings, igniter bomb tests, and full-scale static motor tests.
• Correlate analytical ballistic and ignition models against measured test data (chamber pressure, thrust, ignition delay, burn duration) to refine burn rate property decks and loss factors.
• Lead root‑cause investigations and failure review boards (FRACAS/MRB) for ballistic performance anomalies, such as ignition delay/hangfire, combustion instability, pressure spikes, unpredicted erosive burning, or performance margin degradation.
• Maintain ballistic databases, lot acceptance test (LAT) trends, and motor performance history across production lots.

• Work closely with structural analysts (grain strain/slump), thermal analysts (nozzle erosion/insulation heat flux), nozzle designers, and manufacturing teams to deliver balanced, producible motor designs.
• Author clear ballistic analysis reports (BAR), igniter design specifications, performance verification packages, and qualification test plans.
• Present technical findings, performance trade studies, and ballistic margins at major program milestones (PDR, CDR, TRR, MRB).
• Serve as a technical mentor to junior engineering staff in interior ballistics theory, grain design tools, and pyrotechnic ignition principles.
• Ensure strict compliance with ITAR, EAR, site energetics safety standards, and explosive safety regulations (DoD 4145.26-M).

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Chemical Engineering, or a closely related technical field from an accredited institution.
• Experience:
  • Ballistician / Igniter Engineer: Minimum of 4–6 years of relevant experience in solid rocket motor interior ballistics, grain design, or pyrotechnic ignition systems.
  • Senior Ballistician / Igniter Engineer: 7–10+ years of progressive engineering experience owning SRM ballistic sizing, 3D grain optimization, and igniter design for tactical, strategic, or space launch propulsion.
• Demonstrated expertise in interior ballistics theory, thermochemical tools (NASA CEA), and custom 2D/3D grain design software or scripting environments (Python, MATLAB, Fortran, C++).
• Direct experience designing, sizing, or testing solid rocket motor igniters (pyrogen, BKNO3, black powder, or advanced igniter architectures).
• Hands‑on experience analyzing strand burner, subscale motor, or full‑scale static fire pressure‑time data.
• U.S. Citizenship and ability to obtain and maintain a U.S. Government Secret Security Clearance.

• Master’s Degree or Ph.D. in Aerospace, Mechanical, or Chemical Engineering with a focus on propulsion, combustion, or energetics.
• Active U.S. Government Secret Security Clearance.
• Direct experience modeling ignition transients, flame‑spreading dynamics, or pyrogen internal flow fields.
• Applied experience with CFD tools for internal motor flow, alumina slag deposition, or nozzle two‑phase flow analysis.
• Familiarity with solid propellant chemistry, binder systems (HTPB, CTPB, PEG), energetic plasticizers, and burn rate catalyst tailoring.
• Experience with CAD/CAE environments (SolidWorks, NX, or Creo) for grain geometry modeling and igniter mechanical drawing generation.
• Background supporting production lot acceptance testing (LAT) and motor qualification under MIL‑STD / DoD standards.

• 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.

• 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

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.