Senior Manufacturing Engineer - AP Milling

<div class="content-intro"><p> </p> <p><span data-teams="true"><strong>The future of aerospace and defense starts here. <br></strong></span></p> <p><span data-teams="true"><br>Ursa Major was founded to revolutionize how America and its allies access and apply high-performance propulsion, from hypersonics to solid rocket motors, satellite maneuvering and launch. We design and deliver propulsion and defense systems that solve the most urgent and critical national security demands. </span></p></div><p>Ursa Major is developing cutting‑edge propulsion systems and is seeking an innovative and hands‑on a Senior Manufacturing Engineer. The Engineer in this role will assume technical and operational ownership of manufacturing processes for solid rocket motors, with a primary focus on Ammonium Perchlorate (AP) milling and related powder-handling operations. This role will lead the design, development, qualification, and continuous improvement of AP milling processes that feed directly into propellant manufacturing.</p> <p>The ideal candidate brings deep experience with energetic materials <strong>or</strong> strong experience with fine powder processing in a safety‑critical or regulated environment and is eager to apply that expertise to solid rocket propulsion. This is a hands-on position with significant responsibility for day‑to‑day plant operations, process capability, and long‑term process development.</p> <p><strong>Key Responsibilities</strong></p> <p><strong>Process Ownership &amp; Development</strong></p> <ul> <li>Serve as the <strong>Process Owner</strong> for AP milling and associated powder-handling operations</li> <li>Lead hands-on troubleshooting alongside technicians and engineers on the production floor to resolve complex manufacturing issues, stabilize, and improve processes.</li> <li>Develop, maintain, and enforce process documentation, including:</li> <ul> <li>Manufacturing Process Specifications (MPS)</li> <li>Standard Operating Procedures (SOPs)</li> <li>Work Instructions</li> </ul> <li>Define and maintain Critical Process Parameters<strong> </strong>for AP milling (e.g., particle size distribution, moisture content, bulk density, contamination levels, flowability).</li> <li>Own process change control:</li> <ul> <li>Initiate, justify, and implement process changes via formal ECN mechanisms.</li> <li>Perform risk assessments (FMEA, HAZOP) for proposed changes.</li> <li>Plan and manage validation and requalification activities following changes.</li> </ul> <li>Lead continuous improvement initiatives using Lean, Six Sigma to support:</li> <ul> <li>New propellant formulations and motor programs</li> <li>Scale‑up from development to production volumes</li> <li>Reductions in cycle time, scrap, and variability</li> </ul> <li>Specify and optimize milling equipment and conditions:</li> <ul> <li>Mill type selection (e.g., jet mills, ball mills, pin mills, hammer mills)</li> <li>Operating parameters (feed rates, rotor speeds, classifier settings, media selection, temperature control)</li> </ul> <li>Design, develop, and validate new manufacturing processes and equipment to meet design specifications, safety standards, and production rate requirements for AP milling.</li> <li>Provide technical guidance and mentorship to manufacturing engineers and technicians, promoting best practices in process control, problem solving, and operational excellence.</li> </ul> <p><strong>Safety, Environmental &amp; Regulatory Compliance</strong></p> <ul> <li>Lead in establishing and maintaining <strong>process safety</strong> for energetic and oxidizer handling, with a focus on fine powder hazards.</li> <li>Perform and update Process Hazard Analyses (PHA), HAZOPs, and Job Safety Analyses (JSAs) for AP milling and related processes.</li> <li>Define safe operating envelopes for AP milling (e.g., temperature limits, inert atmosphere requirements, static control, equipment interlocks).</li> <li>Ensure compliance with relevant military/industry standards and regulations for energetic materials, oxidizers, and combustible dusts (e.g., applicable NFPA and OSHA requirements).</li> <li>Support incident/near‑miss investigations and implement corrective and preventive actionsOther duties as assigned</li> </ul> <p><strong>Required Qualifications</strong></p> <p><strong>Education</strong></p> <ul> <li>Bachelor of Science (B.S.) in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Materials Engineering, Aerospace Engineering, or a related field.</li> </ul> <p><strong>Experience</strong></p> <ul> <li>Minimum of <strong>6years</strong> in a manufacturing or process engineering role, developing and deploying new production processes and equipment.</li> <li>Proven hands-on experience with <strong>powder or particulate material processing</strong> in a production environment, such as:</li> <ul> <li>Milling, grinding, jet milling, micronization, classification, sieving, blending, or spray drying.</li> </ul> <li>Demonstrated <strong>process ownership</strong> in a production environment:</li> <ul> <li>Defined, controlled, and improved processes at scale.</li> <li>Implemented and controlled changes via formal documentation and change-control systems.</li> </ul> <li>Experience in at least one of the following:</li> <ul> <li>Solid rocket motor or energetics manufacturing (propellant mixing, casting, curing, machining, powder handling); <strong>or</strong></li> <li>Chemical, pharmaceutical, battery materials, metal powder, or other materials processing involving strict safety, quality, and regulatory controls.</li> </ul> </ul> <p><strong>Skills</strong></p> <ul> <li>Strong understanding of:</li> <ul> <li><strong>Particle technology</strong>: particle size distribution, morphology, flow behavior, segregation, packing, bulk density.</li> <li><strong>Milling and classification operations</strong>: mill selection, operating principles, scale‑up considerations.</li> <li><strong>Process safety for combustible dusts, oxidizers, and/or energetic materials</strong>: dust explosion hazards, static control, inerting, ventilation.</li> </ul> <li>Proficiency with:</li> <ul> <li>Root cause analysis methodologies (5‑Whys, Fishbone, FMEA).</li> <li>Basic statistical tools for process analysis (e.g., SPC, capability analysis), using software such as Minitab, JMP, or equivalent.</li> </ul> <li>Strong written and verbal communication skills, with the ability to generate clear work instructions and to train technicians and operators.</li> <li>Strong proficiency in 3D CAD software (e.g., SolidWorks, Siemens NX, CATIA) for tooling, fixtures, and simple equipment design.</li> <li>Excellent project management skills: able to scope, plan, and execute development and qualification activities with clear milestones and deliverables.</li> </ul> <p><strong>Desired Qualifications</strong></p> <ul> <li>Education: Master of Science (M.S.) in a relevant engineering discipline.</li> </ul> <ul> <li>Direct experience in <strong>solid rocket motor manufacturing</strong>, specifically one or more of:</li> <ul> <li>Powder handling and conveyance systems for oxidizers or energetic materials.</li> <li>Milling and particle size reduction (e.g., jet mills, ball mills, pin mills) for oxidizers or fine powders.</li> </ul> <li>Previous experience in the <strong>aerospace, defense, or energetics industry</strong>, particularly with solid rocket motor manufacturing (insulation, propellant, case winding, or similar processes).</li> <li>Hands-on experience with:</li> <ul> <li>Dust collection and explosion protection systems (e.g., NFPA‑compliant systems, explosion vents, suppression systems, explosion isolation devices).</li> </ul> <li>Familiarity with:</li> <ul> <li>Relevant NFPA standards for combustible dusts and oxidizers.</li> <li>AS9100, ISO 9001, or other quality management systems in a highly regulated industry.</li> <li>Lean / Six Sigma methodologies (Green Belt or above preferred).</li> </ul> </ul> <p>Colorado law requires us to tell you the base compensation range of this role, which is $88,000 - $130,000, determined by your education, experience, knowledge, skills, and abilities. What we <em>can’t </em>quantify for you are the exciting challenges, supportive team, and amazing culture we enjoy. </p> <p>Classification: Full-time Exempt</p><div class="content-conclusion"><div> <div> <p> </p> <p><strong>Benefits Include: (Please note, Interns are not eligible for benefits)</strong></p> <ul> <li>Unlimited PTO - Vacation, Sick, Personal, and Bereavement</li> <li>Paid Parental and Adoptive Leave</li> <li>Medical, Dental and Vision Insurance</li> <li>Tax Advantage Accounts (HSA/FSA)</li> <li>Employer Paid Short and Long Term Disability, Basic Life, AD&amp;D</li> <li>Additional Benefit Options Including Voluntary Life and Emergency Medical Transport</li> <li>EAP Program</li> <li>Retirement Savings Plan - 401k with Company Match</li> <li>Equity Grants in the Company</li> </ul> <p> </p> <p><span data-teams="true"><strong>How To Apply: </strong><br>Interested candidates are encouraged to apply by filling out the application below and clicking "Submit Application". This position will be posted for a minimum of 3 days and will remain open until filled or adjusted based on the volume of applicants.</span></p> <hr></div> <div><strong>NOTE: </strong>Research suggests that women and BIPOC individuals may self-select out of opportunities if they don't meet 100% of the job requirements. We encourage anyone who believes they have the skills and the drive necessary to succeed here to apply for this role.</div> </div> <div> </div> <div><strong>Must be a U.S. Person (this includes U.S. Citizens and Permanent Residents).</strong></div> <div> </div> <div><strong>Eligibility to obtain and maintain a U.S. Security Clearance. </strong></div> <div> </div> <div><em>We’re an equal-opportunity employer. You will be considered for employment without attention to race, color, religion, sex, sexual orientation, gender identity, national origin, veteran, or disability status.</em></div> <div> </div> <div>No outside recruiters, please.</div> <div> </div></div>