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Salary: USD 80,000 - 115,000 / annual
Voyager Technologies, a space, defense, and national security technology company, is seeking a Hazardous Materials Packaging Specialist to design, develop, and implement packaging solutions for energetic materials, propellants, and small solid rocket motors. Reporting to the Materials & Production Planning Manager, this role owns the complete packaging lifecycle—from material selection and design through testing, qualification, and compliance—ensuring products arrive intact, safe, and compliant with all applicable regulations.
Key Responsibilities:
Package Design & Development: Design comprehensive packaging systems including primary containment, interior cushioning, closure systems, and outer shipping containers. Select appropriate materials (fiberboard, wood, steel, aluminum, foam, composites) based on product fragility, weight, chemical compatibility with energetic formulations, and electrostatic properties. Use cushion curve data, fragility assessments, and drop height analysis to size cushioning materials. Engage with propulsion and mechanical engineers early in product development to translate requirements into feasible, cost-effective designs. Produce complete design packages with engineering drawings, material specifications, BOMs, assembly instructions, and Packaging Data Sheets.
Product Protection & Preservation: Define preservation methods (desiccants, moisture barriers, vapor corrosion inhibitors, inert gas purging, hermetic sealing) matched to degradation risks and storage duration. Coordinate with chemists and materials engineers to evaluate compatibility between packaging materials and propellant/explosive formulations. Investigate field returns and damage reports; perform root cause analysis and implement corrective actions.
Packaging Testing & Qualification: Plan and execute qualification testing for new and revised designs, including UN performance tests (drop, stacking, vibration, leakproofness) per UN Manual of Tests and Criteria, ASTM D4169, MIL-STD-2073-1, and MIL-STD-810. Evaluate packaging materials for electrostatic discharge (ESD) risk and verify Hazards of Electromagnetic Radiation to Ordnance (HERO) compliance. Analyze test results and drive iterative improvements until acceptance criteria are met.
Production & Supply Chain Coordination: Align packaging design timelines with production schedules. Train production and shipping personnel on approved procedures and inspection criteria; verify packaged products meet approved configurations before shipment.
Hazmat Compliance & Shipping Documentation: Ensure all designs comply with DOT 49 CFR Parts 100–185, IATA Dangerous Goods Regulations, MIL-STD-2073-1, MIL-STD-129, and ATF explosives requirements. Define hazard labels, placards, and markings; maintain current documentation templates.
Work Environment: Work across office, manufacturing, and warehouse environments with required PPE. Will regularly enter Explosives Safety Quantity Distance (ESQD) arcs and restricted areas. Physical demands include standing, walking, lifting up to 50 pounds, and desk work. May require up to 15% travel to test laboratories, supplier facilities, and military delivery locations. Full-time position on 9/80 schedule (one day off every two weeks).
Requirements:
Basic Qualifications:
- Must be 21 years of age or older
- Must pass pre-employment drug screening and State/Federal background checks
- Eligible to obtain and maintain State and Federal explosives licenses
- 3+ years of experience designing and developing industrial packaging with demonstrated responsibility for product protection during shipment and storage
- Hands-on experience selecting and sizing cushioning materials; familiarity with cushion curve data, fragility assessments, and drop height analysis
- Working knowledge of MIL-STD-2073-1 and UN dangerous goods packaging requirements; DOT 49 CFR hazardous materials regulations knowledge
- Current DOT Hazmat Employee training certificate (49 CFR 172.704) or ability to obtain within 90 days of hire
- Ability to produce clear packaging design documentation (drawings, work instructions, BOMs, test reports); proficiency with standard engineering tools and document control
- Strong attention to detail; hands-on, problem-solving approach; comfortable on manufacturing floor and in restricted storage areas
- Familiarity with ITAR/EAR export control requirements as applied to defense articles
- Ability to obtain and maintain a DoD Secret clearance
- Must be a U.S. citizen, lawful permanent resident, or protected individual eligible for export authorizations
Preferred Qualifications:
- Bachelor's degree in Mechanical Engineering, Packaging Engineering, Aerospace Engineering, or related technical field (or equivalent education/experience combination)
- Experience designing packaging for Class 1 (Explosives) articles, solid rocket motors, pyrotechnic devices, or hazardous defense materials
- Familiarity with MIL-STD-129, MIL-STD-810, and ESD control program requirements for energetic/electro-explosive devices
- Hands-on experience with UN packaging qualification testing per UN Manual of Tests and Criteria or ASTM D4169
- IATA Dangerous Goods Regulations (DGR) certification or Certified Packaging Professional (CPP) designation
- Prior experience in defense manufacturing, ordnance, or aerospace environment; prior military logistics or ordnance background a plus
