Designs, analyzes, prototypes, tests, and integrates propulsion and dispersal hardware for high-acceleration aerospace systems. Responsibilities include solid rocket motor and grain design, internal ballistics, combustion and thermal analysis, high-pressure hardware, valves, sensors, impulse-transfer mechanisms, CFD/CEA/FEA modeling, static fires, pressure and thermal testing, instrumentation, qualification, and cross-functional system integration. The role requires hands-on energetic-materials and propulsion test experience, strict safety compliance, and ownership from concept through qualification.
Overview
What You’ll Do
High-Impulse System & Solid Rocket Motor Design
High-Pressure & High-G Hardware
Dispersal & Impulse Transfer Mechanisms
Simulation & Analysis
Testing & Qualification
Integration & Full System Ownership
Required Qualifications
Nice to Haves
Compensation
Wardstone is looking for a Propulsion Engineer to own the development of the main engine and divert systems that power our first product, Hailstorm. This includes gas generators, micro-thrusters, solid rocket motors (SRMs), high-pressure systems, fast-acting valves, detonation-assisted dispersal systems, and high-temperature/pressure fluid dynamics.
You will design, analyze, prototype, test, and iterate propulsion and dispersal hardware capable of producing extreme accelerations, high mass flow, and low latency response times.
You will work side-by-side with the founders, mechanical, electrical, and controls engineers.
High-Impulse System & Solid Rocket Motor Design
- Design and select compact propulsion and impulse systems: solid rocket motors, gas generators, and cold-gas thrusters.
- Perform solid propellant grain design and 3D burnback geometry analysis to tailor thrust curves (progressive, regressive, neutral).
- Model internal ballistics, combustion, mass flow, chamber pressures, and heat transfer.
- Select appropriate propellant formulations, internal insulation, and ablative nozzle materials to survive extreme thermal environments.
- Evaluate tradeoffs between solid, liquid, or hybrid propulsion architectures for specific interceptor flight regimes.
High-Pressure & High-G Hardware
- Design motor casings, pressure vessels, regulators, burst disks, check valves, fast-response actuators, and timing mechanisms.
- Simulate structural integrity under high G’s and perform empirical testing.
- Integrate sensors (pressure, temperature, vibration) for test instrumentation and feedback.
Dispersal & Impulse Transfer Mechanisms
Co-design the systems responsible for deploying Wardstone’s kinetic interceptor solution.
Model shock propagation, material acceleration, and high-velocity ejecta characteristics.
- Work closely with the detonation/energetics engineer to integrate igniter development (pyrogen/pyrotechnic), hybrid, or explosive-augmented systems.
Simulation & Analysis
- Use CFD, CEA, FEA, and custom simulation tools to evaluate propulsion behavior, including nozzle throat erosion and slag accumulation.
- Run data-driven design cycles: test → instrument → analyze → redesign.
- Define requirements for Δv, rise time, thrust profiles, and thermal durability.
Testing & Qualification
Plan and execute high-G tests, pressure tests, thermal tests, and solid motor static fires.
- Work with external test ranges, explosive facilities, instrumentation teams, and ensure strict safety protocols for handling energetic materials (Class 1.1/1.3).
- Develop test fixtures, data acquisition setups, and high-speed video capture systems.
Integration & Full System Ownership
Collaborate with mechanical engineers on structures that withstand high impulse loads and internal motor pressures.
- Collaborate with electrical engineers on ignition trains (ESDs, EBWs), actuation, and safety interlocks.
- Collaborate with controls engineers on predictor models and impulse sequencing.
Required Qualifications
- B.S. in Aerospace, Mechanical, Chemical Engineering, or a related field.
- Demonstrated experience with propulsion design, combustion, energetics, or high-pressure systems.
- Hands-on experience with solid rocket motor development from concept through static fire, including grain design, igniters, and nozzle integration.
- Hands-on test experience: ignition, valves, tanks, pressure systems, or propulsion rigs.
- Deep understanding of internal flow, combustion, heat transfer, and structural limits.
- Experience designing hardware for missiles, interceptors, rockets, or other aerospace systems.
- US Person or Lawful Permanent Resident status required.
Nice to Haves
- Familiarity with solid propellant chemistry (e.g., APCP, HTPB, double-base) and casting/curing processes.
- Exposure to MIL-STD testing (thermal, vibration, shock, environmental).
- Experience with high-speed DAQ, strain gauges, thermocouples, and high-speed cameras.
- Hands-on build experience: machining, pressure plumbing, test fixture design.
- Strong modeling experience: CEA, CFD (OpenFOAM/ANSYS/COMSOL), MATLAB/Python, or equivalent.
The base pay range for this role is $100,000 – $160,000 per year.
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