Senior NDE Engineer – Solid Rocket Motors

Castelion is seeking a Senior NDE Engineer to own all non-destructive evaluation activities for our solid rocket motor programs. In this role, you will develop, qualify, and deploy advanced inspection techniques capable of detecting critical flaws in large energetic articles while supporting aggressive production rates. You will serve as the technical authority on radiographic, ultrasonic, and emerging NDE methods in a high-hazard, ITAR-regulated environment.

CORE RESPONSIBILITIES

NDE Process Ownership: Own the full NDE lifecycle for solid propellant motors: technique development, procedure creation, personnel training, equipment selection, and daily execution. Establish repeatable, high-confidence inspection processes for propellant voids, case-bond anomalies, liner/insulator disbonds, inhibitor cracks, and nozzle defects.

Advanced Technique Development: Architect and qualify next-generation NDE solutions including digital radiography (DR), computed tomography (CT), phased-array ultrasonics (PAUT), thermography, and shearography. Implement automated defect recognition (ADR) to support rate production.

Inspection Throughput and Automation
Design and implement high-throughput inspection cells (robotic manipulators, conveyorized X-ray, real-time CT reconstruction). Reduce inspection cycle time while maintaining or improving probability of detection (POD) for critical flaw sizes.

Regulatory and Customer Compliance: Author and maintain NADCAP-compliant NDE procedures, technique sheets, and Level III responsibilities. Serve as an interface with customer and regulatory bodies during source inspections, audits, and qualification reviews.

Anomaly Investigation and Material Review Board: Lead NDE support for root-cause investigations of in-process and flight anomalies. Provide rapid, high-fidelity imaging and interpretation to disposition non-conformances and prevent schedule impacts.

Technology Insertion and Capital Planning: Identify, evaluate, and deploy emerging NDE technologies (e.g., high-energy CT for thick-section propellant, AI-assisted ultrasonics). Lead capital projects for new inspection bays, radiation vaults, and explosive-compatible equipment.

Cross-Functional Collaboration: Partner with Manufacturing Engineering to design inspectable features into new motor designs. Work with Quality and EHS to ensure radiation safety, explosive quantity-distance compliance, and personnel qualification.

QUALIFICATIONS

Basic Requirements

• Bachelors degree in Engineering, Physics, Materials Science, or related field.
• Minimum 7 to 10 years of hands-on NDE experience, preferably in the Aerospace industry.
• Active Secret clearance (or ability to obtain). U.S. Person required for ITAR compliance.

Preferred Experience

• Proven track record developing and qualifying NDE techniques for large solid rocket motors (30 in diameter, case-bonded grains).
• Deep expertise in digital radiography systems, high-energy linear accelerators, and industrial CT reconstruction software.
• Experience achieving NADCAP accreditation for NDE in propulsion or explosives environments.
• Hands-on implementation of automated defect recognition and phased-array UT on complex geometries.
• Prior work supporting rapid-response anomaly investigations on strategic or launch vehicle programs.
• Strong aptitude for scripting (Python, MATLAB) to automate image processing and reporting.
• Demonstrated ability to train and certify Level I/II technicians in high-hazard environments.

Leadership Qualities

• Bias to Action and Creative Problem Solving. Desire and experience questioning assumptions in ways that lead to break through ideas that are ultimately implemented. Successfully bring in applicable processes/concepts/materials from other industries to achieve efficiency gains. Ability to personally resolve minor issues in development without requiring significant support.
• High Commitment, High Initiative. A successful candidate will have a genuine passion for Castelion's mission and consistently look for ways to contribute to the company's technical goals and prevent hardware blockers. Ability to work in a fast paced, autonomously driven, and demanding atmosphere. Strong sense of accountability and integrity.
• Clear Communicator. Proactively communicates blockers. Trusted in previous roles to be voice of company with regulators, suppliers, gate keepers and customers. Capable of tactfully managing relationships with stakeholders to achieve company-desired outcomes without compromising relationships. Emails, IMs and verbal interactions are logical, drive clarity, and detailed enough to eliminate ambiguity.