Process Engineer - Pyrotechnics

About UDC

Ultra Defense Corp (UDC) is a privately held defense company headquartered in Tampa, Florida, with domestic manufacturing facilities and operations supporting American national security interests worldwide.

For more than 15 years, UDC has built a stable and mature organization and is now entering a significant period of expansion. With a growing portfolio aligned with U.S. defense priorities, advanced technology, and domestic manufacturing. UDC offers the opportunity to work in an entrepreneurial environment backed by organizational stability and competitive benefits.

The Opportunity

The Process Engineer develops and improves manufacturing processes for pyrotechnic components and devices, including Battlefield Effects Simulators, using energetic materials such as black powder. The role supports production equipment, Bills of Materials, process documentation, proposal development, safety analysis, and product/process improvement. Working cross-functionally with Operations, Quality, Program Management, and other technical experts, the position helps ensure safe, repeatable, compliant, and effective pyrotechnic manufacturing operations.

What You’ll Do

• Develop and implement manufacturing processes for pyrotechnic components and devices, including Battlefield Effects Simulators, using energetic materials such as black powder.
• Develop and maintain work instructions, standard operating procedures, process documentation, and Bills of Materials for new and existing products, including component materials, packaging, and ancillary consumables.
• Work with subject-matter experts to identify and source equipment used to mix, process, press, and produce pyrotechnic products; support setup and optimization of manufacturing equipment and lines.
• Support new-business and proposal efforts through BOM development, process-flow mapping, process development, technical descriptions, and analysis.
• Develop process hazard analyses and safety procedures in accordance with BATFE and OSHA requirements and support compliance with DoD 4145 energetic safety and DoD 5100 security standards.
• Apply chemistry, physics, and materials-science knowledge to troubleshoot, improve, and optimize pyrotechnic manufacturing processes and product performance.
• Create and lead non-destructive testing programs and participate in exploratory efforts involving new pyrotechnic munitions, devices, and systems.
• Support Program Management and Quality Assurance with technical reporting, Physical Configuration Audits, First Article Acceptance Tests, and Lot Acceptance Tests.

What You Bring

Preferred Qualifications

• Bachelor’s degree in Engineering.

• Minimum of 3+ years of experience in process engineering, manufacturing engineering, or a similar position.

• Strong process-development and technical problem-solving experience.

• Experience developing BOMs, process flows, manufacturing instructions, and technical documentation.

• Ability to apply engineering principles, data analysis, experimentation, and risk assessment to manufacturing challenges.

Highly Desired Experience

• Pyrotechnic or energetic-material manufacturing.

• Black powder or similar energetic materials.

• Mixing, processing, pressing, or pyrotechnic production equipment.

• Chemistry, physics, and materials-science applications in manufacturing.

• Process hazard analysis.

• BATFE and OSHA requirements.

• DoD 4145 energetic safety and DoD 5100 security standards.

• Supporting government, customer, or quality audits.

Leadership Profile

The successful candidate will combine strong technical capability with a safety-first mindset and the ability to provide technical leadership across manufacturing, testing, equipment, and process-development initiatives.

We are particularly interested in candidates who demonstrate:

Pyrotechnic Manufacturing | Process Engineering | Technical Leadership | BOM Development | Safety & Risk Management | Technical Communication | Continuous Improvement | Collaboration

Location & Travel

This position is based in Marshall, Texas and will operate primarily in office, production, and laboratory environments. Occasional travel may be required based on business needs.

Additional Requirements

• Must successfully complete required background and drug screening.

• Must be able to pass a BATFE background investigation and secure Employee Possessor eligibility.

• Must comply with applicable CUI, ITAR/EAR, CMMC, cybersecurity, annual compliance, safety, and confidentiality requirements.

• Must be able to safely work around pyrotechnic and energetic materials, specialized equipment, and required PPE.

• Ability to lift up to 40 pounds.

Why UDC?

This position offers the opportunity to directly influence UDC’s pyrotechnic manufacturing capability while helping build safe, repeatable, and scalable production processes supporting defense-related products and programs.

What UDC Offers

• Competitive Base Salary

• Medical, Dental, Vision, STD, LTD, Life & AD&D

• 401(k) & Company Match

• Company Paid Holidays

• Generous Vacation Policy

• Professional Development and Advancement Opportunities

Equal Employment Opportunity Employer

Ultra Defense Corporation is an Equal Employment Opportunity employer.