Principal Propulsion Engineer

The Principal Propulsion Engineer owns the design, analysis, and qualification of propulsion systems across Zone 5’s product line—spanning air-launched effects, tactical interceptors, and next-generation munitions. This role is responsible for ensuring propulsion systems perform reliably under demanding flight, launch, and mission conditions. 

You will work across the full lifecycle—from concept and trade studies through design, test, qualification, and production—partnering closely with GNC, Systems Engineering, Manufacturing, and Integration & Test to deliver robust, scalable propulsion solutions. 

Key Responsibilities 

• Own the technical design and performance of solid rocket motor systems and supporting propulsion subsystems across multiple concurrent programs, from concept through qualification and production 

• Lead internal ballistics, structural, and thermal analysis of motor cases, nozzles, propellant grains, igniters, and ignition safety components 

• Drive static fire test campaigns and ground test infrastructure by defining test plans, instrumentation, and acceptance criteria, and own root-cause investigation when anomalies occur 

• Translate system-level requirements (range, thrust profile, packaging constraints, rail/tube launch loads) into propulsion subsystem specs in close coordination with airframe and GNC 

• Partner with manufacturing and supply chain to design for producibility and scale — Zone 5 builds in quantity, not just for demonstration 

• Develop and maintain technical roadmaps for propulsion product lines, including commonality and cost-reduction strategy across programs 

• Represent propulsion technical status to customers, government stakeholders, and leadership; be the face of the subsystem on your programs 

• Mentor and grow propulsion engineers as the team scales under you; help build the test and design processes that don't yet exist 

• Maintain rigorous documentation, safety, and regulatory compliance for energetics and propulsion systems (handling, transport, range safety) 

Qualifications 

Required 

• B.S. in Aerospace Engineering, Mechanical Engineering, or equivalent.  

• 8+ years of experience in propulsion system design, analysis, or test.  

• Strong experience with solid rocket motor design, including internal ballistics, propellant/grain design, motor case, and nozzle design.  

• Demonstrated ownership of propulsion systems from concept through flight test or production, not analysis in isolation.  

• Experience standing up or running static fire/hot fire test campaigns, including instrumentation, data reduction, and anomaly investigation.  

• Strong technical depth in at least two of: internal ballistics, structural analysis, thermal/ablation analysis, or nozzle design.  

• Familiarization with energetics handling, transport, and range safety requirements.  

• Programming or scripting experience (e.g., MATLAB, Python, or similar) for modeling and data analysis.  

• Strong troubleshooting skills in complex propulsion test environments.  

• Ability to work cross-functionally and communicate effectively across IPTs.  

• Ability to obtain and hold a U.S. DoD Secret security clearance, at minimum.  

Preferred 

• M.S. or Ph.D. in Aerospace Engineering, Mechanical Engineering, or related discipline.  

• Experience with air-launched weapons, tactical missiles, or counter-UAS interceptor systems specifically.  

• Experience with liquid or hybrid propulsion systems in addition to solid rocket motors.  

• Experience taking a propulsion system from a startup/low-rate environment into scaled or high-rate production.  

• Track record building or growing a propulsion team or function from the ground up.  

• Familiarity with MOSA/WOSA architectures or modular weapon platforms.  

• Direct relationships with solid rocket motor suppliers, energetics manufacturers, or DoD propulsion test ranges.  

• Active or eligible for U.S. DoD Secret or Top Secret security clearance.