Senior Manufacturing Engineer - AP Milling

The future of aerospace and defense starts here.

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.

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.

• •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

• •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

• •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.