Senior Manufacturing Engineer - AP Milling

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.

The ideal candidate brings deep experience with energetic materials or 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.

Key Responsibilities

Process Ownership & Development

• Serve as the Process Owner for AP milling and associated powder-handling operations
• Lead hands-on troubleshooting alongside technicians and engineers on the production floor to resolve complex manufacturing issues, stabilize, and improve processes.
• Develop, maintain, and enforce process documentation, including:
• Manufacturing Process Specifications (MPS)
• Standard Operating Procedures (SOPs)
• Work Instructions
• Define and maintain Critical Process Parameters for AP milling (e.g., particle size distribution, moisture content, bulk density, contamination levels, flowability).
• Own process change control:
• Initiate, justify, and implement process changes via formal ECN mechanisms.
• Perform risk assessments (FMEA, HAZOP) for proposed changes.
• Plan and manage validation and requalification activities following changes.
• Lead continuous improvement initiatives using Lean, Six Sigma to support:
• New propellant formulations and motor programs
• Scale‑up from development to production volumes
• Reductions in cycle time, scrap, and variability
• Specify and optimize milling equipment and conditions:
• Mill type selection (e.g., jet mills, ball mills, pin mills, hammer mills)
• Operating parameters (feed rates, rotor speeds, classifier settings, media selection, temperature control)
• Design, develop, and validate new manufacturing processes and equipment to meet design specifications, safety standards, and production rate requirements for AP milling.
• Provide technical guidance and mentorship to manufacturing engineers and technicians, promoting best practices in process control, problem solving, and operational excellence.

Safety, Environmental & Regulatory Compliance

• Lead in establishing and maintaining process safety for energetic and oxidizer handling, with a focus on fine powder hazards.
• Perform and update Process Hazard Analyses (PHA), HAZOPs, and Job Safety Analyses (JSAs) for AP milling and related processes.
• Define safe operating envelopes for AP milling (e.g., temperature limits, inert atmosphere requirements, static control, equipment interlocks).
• Ensure compliance with relevant military/industry standards and regulations for energetic materials, oxidizers, and combustible dusts (e.g., applicable NFPA and OSHA requirements).
• Support incident/near‑miss investigations and implement corrective and preventive actionsOther duties as assigned

Required Qualifications

Education

• Bachelor of Science (B.S.) in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Materials Engineering, Aerospace Engineering, or a related field.

Experience

• Minimum of 6years in a manufacturing or process engineering role, developing and deploying new production processes and equipment.
• Proven hands-on experience with powder or particulate material processing in a production environment, such as:
• Milling, grinding, jet milling, micronization, classification, sieving, blending, or spray drying.
• Demonstrated process ownership in a production environment:
• Defined, controlled, and improved processes at scale.
• Implemented and controlled changes via formal documentation and change-control systems.
• Experience in at least one of the following:
• Solid rocket motor or energetics manufacturing (propellant mixing, casting, curing, machining, powder handling); or
• Chemical, pharmaceutical, battery materials, metal powder, or other materials processing involving strict safety, quality, and regulatory controls.

Skills

• Strong understanding of:
• Particle technology: particle size distribution, morphology, flow behavior, segregation, packing, bulk density.
• Milling and classification operations: mill selection, operating principles, scale‑up considerations.
• Process safety for combustible dusts, oxidizers, and/or energetic materials: dust explosion hazards, static control, inerting, ventilation.
• Proficiency with:
• Root cause analysis methodologies (5‑Whys, Fishbone, FMEA).
• Basic statistical tools for process analysis (e.g., SPC, capability analysis), using software such as Minitab, JMP, or equivalent.
• Strong written and verbal communication skills, with the ability to generate clear work instructions and to train technicians and operators.
• Strong proficiency in 3D CAD software (e.g., SolidWorks, Siemens NX, CATIA) for tooling, fixtures, and simple equipment design.
• Excellent project management skills: able to scope, plan, and execute development and qualification activities with clear milestones and deliverables.

Desired Qualifications

• Education: Master of Science (M.S.) in a relevant engineering discipline.
• Direct experience in solid rocket motor manufacturing, specifically one or more of:
• Powder handling and conveyance systems for oxidizers or energetic materials.
• Milling and particle size reduction (e.g., jet mills, ball mills, pin mills) for oxidizers or fine powders.
• Previous experience in the aerospace, defense, or energetics industry, particularly with solid rocket motor manufacturing (insulation, propellant, case winding, or similar processes).
• Hands-on experience with:
• Dust collection and explosion protection systems (e.g., NFPA‑compliant systems, explosion vents, suppression systems, explosion isolation devices).
• Familiarity with:
• Relevant NFPA standards for combustible dusts and oxidizers.
• AS9100, ISO 9001, or other quality management systems in a highly regulated industry.
• Lean / Six Sigma methodologies (Green Belt or above preferred).

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 can’t quantify for you are the exciting challenges, supportive team, and amazing culture we enjoy.

Classification: Full-time Exempt

Benefits Include: (Please note, Interns are not eligible for benefits)

Must be a U.S. Person (this includes U.S. Citizens and Permanent Residents).

Eligibility to obtain and maintain a U.S. Security Clearance.