Test Engineer

Prometheus Energetics is seeking an experienced Test Engineer / Senior Test Engineer to serve as a primary technical authority for solid rocket motor test operations, owning the design, integration, commission, and lifecycle support of propulsion and energetic test infrastructure. Reporting directly to the Director of Engineering, this role establishes an independent, high-rigor test engineering capability as Prometheus Energetics transitions from facility startup into high-rate production. The role encompasses the full spectrum of SRM test execution-from development and R&D static fires through formal qualification, production acceptance, and flight test support. The ideal candidate brings 4 to 10 years of hands-on propulsion test stand operations, data acquisition architecture, hazard containment, and test-like-you-fly (TLYF) execution experience, ensuring the highest standards of safety, data fidelity, and mission success. Key Responsibilities Test Infrastructure Design, Integration & Controls

• Design, develop, commission, and sustain scalable propulsion test stands and ground support equipment (GSE) supporting subscale, development, qualification, and production acceptance static firings.
• Design and integrate high-pressure pneumatic, hydraulic, and fluid delivery systems for remotely operated test stand configurations.
• Architect industrial electrical and control systems for test cell operations, including low-voltage power distribution, grounding/bonding, safety interlocks, PLC automation (e.g., Siemens/Allen-Bradley), and abort logic.
• Select, integrate, and maintain high-speed data acquisition (DAQ) hardware (kHZ to MHz sampling rates) and sensor suites, including load cells, high-frequency pressure transducers, thermocouples, accelerometers, strain gauges, and radiometers.
• Develop and maintain automated test control sequences, DAQ configurations, and data processing tools using LabVIEW, Python, MATLAB, or PLC-based control logic.

Test Planning, Execution & Operations

• Lead the development of comprehensive test plans, standard operating procedures (SOPs), hazard analyses, pre-fire checklists, and countdown sequences for motor static firings and environmental screening (vibration, thermal, shock).
• Serve as Test Conductor or Lead Test Engineer during energetic operations, directing console operators, managing countdowns, and enforcing range and safety perimeters.
• Execute static fire campaigns, real-time telemetry monitoring, and immediate post-test safing, ensuring safe containment of toxic combustion products and high-pressure hardware.
• Champion Test-Like-You-Fly (TLYF) practices, ensuring ground test environments, line losses, and instrumentation configurations accurately reflect flight operational profiles.
• Support production acceptance testing (PAT) and scale test operations to support rapid motor production throughput.

Data Analysis, Reporting & Anomaly Resolution

• Process, filter, and analyze raw test data to deliver rapid post-fire summary packages, evaluating pressure-time traces, thrust curves, total impulse, ignition delay, and thermal/vibration environments.
• Correlate measured test data against predicted ballistic, thermal, and structural analytical models in collaboration with ballisticians and structural analysts.
• Lead root-cause investigations and failure review boards (FRACAS/MRB) for test cell anomalies, facility hardware failures, DAQ dropouts, or unpredicted motor performance behavior.
• Maintain rigorous test stand documentation, including sensor calibration logs, channel lists, facility P&IDs, electrical schematics, and test execution history.

Cross-Functional Collaboration & Safety Leadership

• Partner closely with Propulsion, Manufacturing, Quality, Ballistics, and EHS teams to ensure hardware test-readiness and design-for-testability (DFT).
• Strictly enforce explosive safety regulations, including DoD 4145.26-M, range safety requirements, ordnance handling protocols, and pressure vessel safety standards.
• Participate in formal design reviews (PDR, CDR, TRR) to provide test perspective, instrumentation access plans, and verification evidence.
• Mentor junior test engineers and technicians, fostering a culture of operational discipline, safety, and technical excellence.

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Chemical Engineering, or a related engineering discipline from an accredited university. (Associate’s degree with 5+ years of relevant SRM experience may be considered in lieu of a bachelor’s degree.), * Test Engineer: Minimum of 4-6 years of hands-on experience in propulsion testing, energetic materials handling, rocket motor static firing, or high-hazard aerospace test operations.

• Senior Test Engineer: 7-10+ years of progressive experience owning test stand infrastructure, high-speed DAQ architecture, thrust stand design, and serving as Test Conductor for energetic operations.

• Instrumentation & DAQ: Proven expertise in selecting, installing, calibrating, and troubleshooting high-frequency sensors (pressure transducers, load cells, TCs, accelerometers) and high-speed DAQ architecture.
• Controls & Automation: Proficiency with high-speed data acquisition software and industrial control logic (e.g., LabVIEW, MATLAB, NI PXI/CompactDAQ, Dewesoft, or PLC platforms like Siemens).
• Hazardous Operations: Direct experience with explosive safety standards (DoD 4145.26-M or equivalent), high-pressure pneumatic systems (ASME/DOT), and hazardous material handling.
• Regulatory: U.S. Citizenship required (position involves ITAR/EAR restricted technology).
• Clearance: Ability to obtain and maintain a U.S. Government Secret Security Clearance., * Master’s degree in aerospace, Mechanical, or Electrical Engineering.
• Active U.S. Government Secret Security Clearance.
• Certified Test Conductor background with experience leading hazardous countdowns for solid rocket motor or liquid engine static firings.
• Direct experience designing or commissioning thrust structures, thrust vector control (TVC) restraints, or subscale energetic test beds.
• Applied experience with Python or MATLAB for automated test data processing, signal filtering, and plot generation.
• Familiarity with CAD/CAE tools (SolidWorks, NX, or Creo) for test fixture and facility ground support equipment design.
• Experience in facility startup or production ramp environments, standing up new propulsion test stands from concept to operational readiness.

Work Environment & Physical Requirements

• Work is performed in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas subject to enhanced safety and security controls.
• Must be able to wear required personal protective equipment (PPE) and comply with site safety, explosive-safety, electrostatic discharge (ESD), and access-control requirements.
• Ability to move throughout a manufacturing site, inspect physical tooling, participate in shop-floor audits, and occasionally lift up to 25 pounds.
• Regular, reliable attendance is required. Periodic travel to vendor machine shops, secondary company facilities, or customer sites may be required during startup, tool qualification, or critical production events.

• Medical, dental, and vision insurance
• Life and AD&D insurance; short- and long-term disability coverage
• 401(k) savings plan
• Paid time off and company holidays