R&D Technician

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.

R&D Technician

We are seeking an R&D Technician to support hands-on solid rocket motor (SRM) manufacturing and testing operations at Castelion's development site. Reporting to the Development Site Operations Manager, this role is critical to the safe and effective execution of propellant processing, motor assembly, test setup, and development testing for hypersonic programs including Blackbeard. You will work closely with manufacturing engineers, test engineers, and operations leadership to execute procedures, operate equipment, collect data, and maintain a high standard of safety and quality in a fast-paced R&D environment involving energetic materials.

Responsibilities

• Execute hands-on propellant manufacturing and SRM assembly tasks according to approved work instructions, including material handling, mixing support, casting operations, curing, and component integration.
• Support test setup, instrumentation installation, hardware preparation, and execution of static fire, environmental, functional, and other development tests under the direction of test engineers and the Site Operations Manager.
• Operate, monitor, and perform basic maintenance on manufacturing and test equipment (mixers, casting systems, ovens, test stands, data acquisition systems, and related tooling).
• Collect, document, and organize process and test data; assist with post-test hardware recovery, inspection, and data packaging.
• Strictly follow all energetic materials handling, explosive safety, lockout/tagout, and site-specific safety protocols; actively contribute to a strong safety culture.
• Maintain cleanliness, organization, and readiness of manufacturing and test areas; support 5S and continuous improvement activities.
• Assist with equipment qualification, process trials, procedure validation, and troubleshooting under engineering guidance.
• Prepare and stage materials, tooling, and hardware for builds and tests; support inventory control and material tracking.
• Collaborate daily with engineers, operators, and the Site Operations Manager to meet schedule, quality, and safety objectives.
• Support cross-training and knowledge sharing as the development site scales capabilities and processes.

Basic Qualifications

Education:

• High school diploma or equivalent required. Associate's degree, technical certificate, or equivalent military/technical training in manufacturing, mechanical, electrical, or related field preferred.

Experience:

• 3+ years of hands-on experience in manufacturing, assembly, testing, or operations in aerospace, defense, propulsion, chemical processing, or other high-hazard industrial environments.
• Experience working with energetic materials, hazardous chemicals, or high-consequence processes is highly desirable.

Technical Skills

• Ability to follow detailed work instructions, engineering drawings, and test procedures accurately.
• Hands-on mechanical aptitude with experience using hand tools, power tools, measuring instruments, and basic shop equipment.
• Comfort operating or supporting process equipment (mixers, ovens, presses, or similar) and test-related systems.
• Basic familiarity with data collection, instrumentation, or computer-based logging systems.
• Strong attention to detail, documentation discipline, and ability to work safely in a regulated environment.
• Physical ability to lift and handle hardware (typically up to 50 lbs), work in standing positions for extended periods, and operate in industrial/test environments.

Preferred Skills and Experience

• Direct experience supporting solid rocket motor, propellant, munitions, or missile manufacturing or testing.
• Background in aerospace or defense R&D or production environments.
• Experience with static fire testing, environmental testing, or range operations support.
• Prior work in energetic materials facilities or with ATF/DoD explosive safety requirements.
• Familiarity with lean manufacturing, 5S, or continuous improvement practices.
• Experience in a fast-paced startup or development environment.

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 View email address on aiapply.co. 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.