Energetics Safety Manager

Why Castelion, Why Now 

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability. 

This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.  

Energetics Safety Manager

The Energetics Safety Manager leads Castelion's enterprise Energetics Safety Program and is responsible for establishing the policies, standards, procedures, training, and risk management framework needed to support the safe design, manufacture, storage, transportation, testing, and disposal of energetic materials.

As part of the Environmental, Health & Safety organization, this role provides independent energetics safety oversight and partners with Engineering, Manufacturing, Test, Facilities, Security, Supply Chain, Quality, and Program Management to integrate safety throughout the product and operational lifecycle. The position supports and coordinates energetics safety across all Castelion locations conducting energetic operations.

Responsibilities

Energetics Safety Program

• Lead the development, implementation, and continuous improvement of Castelion's Energetics Safety Program.
• Establish and maintain company-wide policies, standards, procedures, specifications, and training for energetic operations.
• Promote consistent practices across manufacturing, ground test, flight test, storage, transportation, and disposal activities.
• Incorporate lessons learned, regulatory changes, and industry practices into program improvements and the broader EHS Management System.

Energetics Risk Management

• Develop and maintain processes for identifying, evaluating, documenting, and managing risks associated with energetic materials and operations.
• Lead or facilitate qualitative and quantitative hazard analyses, including PHAs, HAZOPs, FMEAs, What-If analyses, QRAs, and Quantity-Distance evaluations, as appropriate.
• Support facility siting, hazard classification, blast and fragmentation assessments, consequence analysis, and operational readiness activities.
• Partner with Engineering and Operations to develop risk reduction strategies using sound engineering principles and the hierarchy of controls.
• Ensure residual risks, assumptions, and required safeguards are clearly documented and elevated through the appropriate risk acceptance process.

Safety Integration & Operational Support

• Lead the integration of energetics safety across engineering, manufacturing, and test operations without assuming ownership of technical design or operational execution.
• Establish standardized approaches for safely conducting energetic manufacturing, ground test, and flight test activities.
• Coordinate energetics safety support for major test campaigns and other high-consequence operations to ensure personnel, facilities, equipment, and safeguards are aligned.
• Support operations conducted at external ranges and ensure alignment with applicable customer and range safety requirements.

Engineering & Test Review Participation

• Represent EHS as a key stakeholder throughout the engineering and operational lifecycle.
• Participate in design reviews, manufacturing and production readiness reviews, operational readiness reviews, and ground and flight test readiness reviews.
• Evaluate whether energetics hazards, risk controls, and verification requirements are appropriately identified and addressed before execution.
• Provide independent recommendations regarding energetics risk, operational safeguards, and residual risk acceptance while preserving Engineering's authority over technical design decisions.

Regulatory Compliance & Governance

• Lead enterprise compliance with applicable energetics and explosives safety requirements.
• Interpret and implement applicable DoD explosives safety standards, DoD 4145, ATF, OSHA, DOT, NFPA, and federal, state, local, customer, and range-specific requirements.
• Develop compliance strategies, maintain required documentation, and support regulatory inspections, customer audits, government reviews, and explosives safety approvals.

Training & Continuous Improvement

• Develop and maintain Castelion's Energetics Safety Training Program, including qualification and competency expectations based on operational hazards and regulatory requirements.
• Lead or support investigations involving energetic materials, identify root and contributing causes, and ensure corrective and preventive actions are implemented.
• Integrate lessons learned into standards, procedures, training, and future design and operational reviews.
• Track leading and lagging indicators, identify trends, and implement improvements that strengthen safety performance and operational effectiveness

Basic Qualifications

• Bachelor's degree in engineering, Occupational Safety, Chemistry, Physics, or a related technical discipline.
• Eight or more years of progressively responsible experience supporting energetic materials or explosives operations in aerospace, defense, military, manufacturing, or another high hazard industry.
• Demonstrated experience developing or implementing energetics safety programs, technical standards, procedures, and operational requirements.
• Experience leading or facilitating hazard analyses and risk assessments, including qualitative and quantitative methodologies such as PHAs, HAZOPs, FMEAs, What-If analyses, QRAs, and Quantity-Distance evaluations.
• Experience participating in multidisciplinary design reviews, readiness reviews, and high consequence test or manufacturing activities.
• Working knowledge of applicable DoD explosives safety requirements, ATF regulations, OSHA, DOT hazardous materials regulations, and NFPA codes and standards.
• Ability to provide independent safety oversight, influence cross-functional teams, and communicate risk-based recommendations without direct operational or engineering authority.
• Strong written, verbal, and interpersonal communication skills

Preferred Skills and Experience

• Experience supporting solid rocket motor manufacturing, propulsion systems, missile programs, or other energetic defense applications.
• Experience supporting ground and flight test operations, external government test ranges, explosives safety approvals, facility siting, or quantitative consequence modeling.
• Professional certification such as CSP, CIH, CHMM, or equivalent.
• Active Secret security clearance or the ability to obtain one.

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.  

Other Duties 

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice. 

Additional Eligibility Requirements 

This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply. 

Affirmative Action/EEO Statement 

Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law. 

Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact [email protected]. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law. 

Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation. 

EAR/ITAR Requirements 

This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.