Senior Manufacturing Engineer - Warhead Integration & Test

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 were building a world-class team to turn bold ideas into real capability.

This is a rare opportunity to join at an early stage where youll 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.

Senior Manufacturing Engineer Warhead Integration & Test

Castelion is seeking an experienced Materials & Process Engineer to serve as the companys technical authority for solid rocket motor propellant. This individual will play a critical role in developing qualifying and scaling propellant formulations and manufacturing processes to meet performance production rate and safety requirements.

The successful candidate will bring deep expertise in energetic materials along with hands-on experience in propellant formulation production-scale process development and characterization.

Responsibilities

• Lead warhead assembly integration and functional test processes for explosive loading fuze integration arming/safing mechanisms and missile-interface mating.

• Develop and execute comprehensive integration & test plans covering component-level subassembly and full-warhead verification (including non-destructive inspection leak testing electrical continuity and safe-arm validation).

• Design and qualify production tooling fixtures automated work cells and test stands for precision explosive handling potting and environmental stress screening.

• Execute Design for Manufacturability (DFM) PFMEA control plans and statistical process control (SPC) to drive first-pass yield >98% and cycle-time reduction.

• Perform root-cause analysis and corrective actions for integration/test failures using 8D fault-tree and FRACAS methods; support MRB/FRB and explosive safety reviews.

• Author and maintain manufacturing work instructions test procedures travelers and quality records compliant with AS9100 MIL-STD-810 and customer requirements.

• Scale production lines from prototype to high-rate manufacturing including capacity modeling facility layout and cost-reduction initiatives.

• Collaborate with suppliers on energetic materials and fuze components; implement incoming inspection and supplier quality improvements.

• Drive continuous improvement and technology insertion to support next-generation hypersonic warhead programs.

Basic Qualifications

• Bachelors degree in Manufacturing Engineering Mechanical Engineering Materials Science or related field.
• 7 years in manufacturing engineering for complex aerospace or defense hardware.

• 4 years specifically supporting warhead munitions or energetic-systems integration and test (or equivalent high-reliability explosive assembly).

• Proven success transitioning warhead or ordnance hardware from prototype through LRIP to full-rate production.

Preferred Skills and Experience

• Direct work on DoD warhead programs hypersonic strike systems or conventional munitions.

• Experience in fast-paced defense environments.

• Background with insensitive munitions (IM) shaped-charge or multi-mode warhead designs.

• Familiarity with ITAR-controlled programs ATF regulations and classified manufacturing protocols.

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 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 candidates 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.

Required Experience:

Senior IC