Staff Nozzle Design Engineer, Solid Rocket Motors

We are seeking a Staff Nozzle Design Engineer with specialized expertise in Thrust Vector Control (TVC) and moveable nozzle solutions to join our propulsion engineering team. In this role, you will lead the mechanical design, kinematic analysis, integration, and testing of advanced vectoring nozzle assemblies for Solid Rocket Motor (SRM) applications.

You will act as the technical lead for complex TVC mechanisms, managing everything from internal aerodynamic throat profiles and structural components to electromechanical actuation loops. The ideal candidate has deep hands-on experience with diverse moveable nozzle architectures and a proven track record of bringing vectoring propulsion systems through static and flight testing.

Primary Responsibilities

Moveable Nozzle Design: Architect and design advanced moveable nozzle configurations for SRMs, applying deep expertise in flexseal (flexible bearing), trapped ball, and split-line structural joints.

TVC Component Integration: Lead the selection, integration, and structural mounting of high-performance Electromechanical Actuators (EMAs) and feedback sensors, specifically Linear Variable Differential Transformers (LVDTs) and string pots.

Kinematic & Structural Analysis: Perform kinematic, clearance, vectoring envelope analyses, and duty cycle modeling.  Optimize structural components (housing, exit cones, throat supports) for high-pressure, high-thermal, and dynamic structural environments.

Material Selection: Select and specify advanced materials for high-temperature environments, including carbon-phenolics, refractory metals, structural composites, and elastomeric compounds for flexible joints.

Test & Verification: Author and execute test plans for TVC subsystems. Lead bench-level actuation and acceptance testing, structural proof tests, and vectoring profiles during rocket motor static tests.

Supplier & Customer Interface: Manage technical requirements with EMA/LVDT sub-tier suppliers. Present design maturity, risk assessments, and test data at major milestones (PDR, CDR, MRR) to leadership and military stakeholders.

Basic Qualifications

Education: Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related STEM discipline.

Experience: Minimum of 7+ years of experience in rocket propulsion design, with at least 4 years dedicated specifically to moveable nozzle or TVC system design.

Technical Depth: Demonstrated experience designing and analyzing at least two of the following: flexseal/flexible bearings, trapped ball joints, or split-line nozzle architectures.

Security: Must be a U.S. Citizen with the ability to obtain and maintain a Department of Defense (DoD) Secret Security Clearance.

Preferred Qualifications

Active DoD Secret or Top Secret Clearance.

Direct experience correlating flight/test telemetry data with pre-test kinematic and structural models.

Strong familiarity with TVC nozzle bench testing, non-destructive inspection (NDI) methods for carbon-phenolic layups and elastomeric flexible bearings.

Proficiency with advanced CAD tools (e.g., Creo, NX) and finite element analysis (FEA) software for thermal-structural coupled analysis (e.g., ANSYS).

Colorado law requires us to tell you the base compensation range of this role, which is $143,360 - $179,200, 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