Site Operations Manager
Why Castelion, Why Now
Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.
This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.
Site Operations Manager
We are seeking a Site Operations Manager to own end-to-end operations of Castelion's R&D manufacturing and testing site for solid rocket motors (SRMs). This leadership role is responsible for the safe, efficient, and high-quality execution of propellant manufacturing, motor assembly, and testing activities supporting prototype, development, and early production hardware for hypersonic programs including Blackbeard. You will lead a multidisciplinary team of engineers, technicians, and operators; drive operational excellence across manufacturing and test; and ensure the site delivers on aggressive development schedules while maintaining the highest standards of energetic materials safety, quality, and compliance. This position serves as the primary operational leader for the development site and partners closely with Propulsion Design, Manufacturing Engineering, Test Engineering, Quality, and Program Management.
Responsibilities
- Own day-to-day operations of the development site, including propellant manufacturing (mixing, casting, curing), SRM assembly/integration, and testing (static fire, environmental, functional, and related development tests).
- Lead, mentor, and develop a high-performing team of manufacturing engineers, test engineers, technicians, and operators; foster a strong safety culture and continuous improvement mindset.
- Develop and execute site operational plans, schedules, and resource allocation to meet program milestones for R&D builds and testing campaigns.
- Drive process maturity, yield improvement, throughput, and cost efficiency while transitioning processes from R&D/prototype to more repeatable production-ready methods.
- Ensure rigorous compliance with energetic materials handling, DoD 4145.26-M, ATF regulations, ITAR, range safety, and all site-specific explosive safety and environmental standards.
- Oversee facility readiness, equipment uptime, maintenance coordination, and capital planning for mixers, casting systems, test stands, instrumentation, and support infrastructure.
- Partner with Test Engineering and Propulsion teams to plan, resource, and execute safe and effective static fire and other development tests; support post-test data reviews and anomaly resolution.
- Collaborate cross-functionally with Design, Manufacturing Engineering, Quality, Supply Chain, and Automation teams on new product introduction, process changes, and design-for-manufacturability/testability feedback.
- Lead root-cause investigations, corrective actions, and continuous improvement initiatives across manufacturing and test operations.
- Support capability expansion and knowledge transfer as processes scale to higher-rate production sites (including Project Ranger in New Mexico).
Basic Qualifications
- Bachelor's degree in Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Manufacturing Engineering, Industrial Engineering, or related technical field.
- 10+ years of progressive experience in manufacturing, operations, or test leadership within aerospace, defense, propulsion, or energetic materials environments.
- 5+ years in a supervisory or management role leading teams responsible for production, R&D manufacturing, or testing operations.
- Demonstrated experience owning or significantly contributing to solid rocket motor, propellant, or analogous high-hazard manufacturing and testing operations.
- Working knowledge of solid rocket motor manufacturing processes (propellant mixing/casting, composite case integration, assembly) and development testing (static fire, instrumentation, data acquisition).
- Familiarity with facility and equipment management for energetic materials operations, including safety systems and hazardous process controls.
- Ability to interpret engineering drawings, process specifications, test plans, and quality requirements.
- Working knowledge of ERP/MES systems, configuration management, and production control practices.
Preferred Skills and Experience
- Direct leadership experience in solid rocket motor or missile propulsion R&D manufacturing and testing environments.
- Background in fast-paced aerospace or defense organizations (startups or primes) with aggressive development timelines.
- Experience standing up or scaling new manufacturing/test capabilities or facilities.
- Prior responsibility for energetic materials safety programs, ATF compliance, or range safety interfaces.
- Familiarity with ITAR-controlled programs and classified operations.
- Experience supporting transition of processes from development site to higher-rate production facilities.
Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.
Other Duties
Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.
Additional Eligibility Requirements
This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.
Affirmative Action/EEO Statement
Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law.
Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact hr@castelion.com. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law.
Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation.
EAR/ITAR Requirements
This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.
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