Process Engineer (Propulsion) in London

Help Build Europe's Hypersonic Capability

Hypersonica , we’re redefining what’s possible in European defence technology.

We exist to deliver speed, resilience, and technological independence at a pace that sets a new standard.

We are a small, elite team working on problems that matter, and solving them fast.

By joining

Hypersonica , you’re not stepping into a predefined role.

You’re joining a talent dense environment where every individual shapes the direction of the company.

Our philosophy is to hire a small number of exceptional people with broad, deep technical capability, strong judgement, and the ability to operate autonomously.

We hire for talent, not rigid boxes.

This role represents a business need, but the way it evolves will be shaped by the individual.

If you’ve achieved what others said was impossible, or you bring a unique combination of skills that doesn’t fit a traditional mould, we want to hear from you.

The work you do here directly contributes to Europe’s technological independence.

What you'll do

• Define the end-to-end manufacturing pathway for the rocket motor, from reception of hardware through to delivery of the completed motor, owning the process from first principles.
• Plan the optimal sequence and layout of operations to minimise component waiting time and keep material flowing efficiently through the site.
• Define how the manufacturing process remains compliant with safety legislation, establishing this early so it shapes the process rather than constraining it after the fact.
• Apply Process Failure Mode and Effect Analysis (PFMEA), Control Plans, and Production Part Approval Process (PPAP) to build robust, repeatable manufacturing processes.
• Own compliance to COSHH, ITAR, and COMAH within the manufacturing process design, working closely with safety, quality, and engineering teams.
• Work hands-on across the shop floor, from early process trials through full-rate production, supporting build, troubleshooting, and continuous improvement.
• Partner closely with propulsion, quality, and safety teams to ensure manufacturing processes are safe, compliant, and ready to scale.
• Use production feedback to continuously refine processes, eliminate bottlenecks, and reduce risk.

Who you are

• A manufacturing engineer with experience in high volume manufacturing of explosive materials.
• Experienced in Manufacturing Engineering within an ISO 9001 environment.
• Skilled in PFMEA, Control Plan, and PPAP, and comfortable applying them to define new processes from scratch.
• Experienced defining processes in compliance with COSHH, ITAR, and COMAH legislation.
• Someone who understands how process design decisions show up in safety, throughput, and compliance, and designs accordingly.
• Able to balance engineering rigour with startup speed, making sound decisions with incomplete data.
• Motivated by building core capability from the ground up in a small team where your processes directly affect production success.
• Energised by responsibility, ownership, and seeing your work move from concept to full-rate production.
• Security and Elibigility Requirement

Due to the nature of the work with the UK MOD, applicants must be a British Citizen (or Dual UK national with British citizenship) and eligible for UK Security Clearance (SC) and, where required, Developed Vetting (DV)

What we offer

• A mission driven environment with the opportunity to work on one of Europe's most consequential defence challenges, with direct impact on sovereign capability and security.
• Daily collaboration with top experts across engineering, operations, and defence, with real opportunity to learn from the best, contribute, and grow.
• High ownership and autonomy; no time tracking, no micromanagement, just clear objectives and accountability for outcomes.
• A fast paced environment where good ideas are implemented quickly, and feedback from production drives real decisions.
• A culture that values clarity, integrity, and excellence, and supports people who take initiative and push boundaries responsibly.
• Competitive compensation and real share options aligned to responsibility and impact, not tenure or hierarchy.

At Hypersonica, every hire raises the bar.

We are deliberately small, intensely capable, and deeply mission-driven.

If this role feels like a strong fit, or if you believe you bring something exceptional that goes beyond the description, we encourage you to apply.

Hypersonica is an equal-opportunity employer and assesses candidates solely on merit, capability, and potential.

You can apply directly to this role or reach out to Nathan Sweeney, Head of Talent.

We review every application and aim to respond to all candidates within two weeks, whether the answer is yes or no.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information.

These tools assist our recruitment team but do not replace human judgment.

Final hiring decisions are ultimately made by humans.

If you would like more information about how your data is processed, please contact us.