Senior Mechanical Engineering- System Design

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.
Senior Mechanical Design Engineer (RF Systems & Radomes)
We are seeking a Senior Mechanical Design Engineer to design and deliver RF-critical structures and packaging for Castelions long-range hypersonic strike vehicles. This role is focused on radome development and RF subsystem integration ensuring structural integrity and thermal survivability while preserving RF performance. You will work hands-on with multidisciplinary engineering teams to design analyze build and validate radomes and RF packaging solutions in a fast-paced hardware-driven environment.
Design and develop RF-transparent structures including radomes windows and associated support structures for high-speed flight vehicles
Lead the architecture and detailed design of RF subsystem packaging including mounting alignment and environmental protection of antennas seekers and electronics
Perform structural and thermal analyses to ensure performance and reliability under extreme aerothermal pressure and dynamic environments
Work closely with RF avionics materials and thermal teams to ensure designs meet RF performance requirements (e.g. transmission reflection boresight error) while maintaining structural integrity
Develop and analyze interfaces between radomes TPS and primary structure including sealing attachment and thermal isolation strategies
Conduct tolerance analysis and assess alignment sensitivity and deformation impacts on RF performance
Support prototyping assembly and hardware bring-up including troubleshooting and root cause analysis of structural and RF performance issues
Define and execute qualification and environmental test plans including thermal vibration and RF testing
Optimize designs for mass thermal performance RF transparency and manufacturability
Mentor junior engineers and contribute to best practices in RF structure and packaging design
Bachelors Masters or PhD in Mechanical Engineering or related field

• 5 years of experience in mechanical design for aerospace or high-performance systems
• Experience designing radomes RF-transparent structures or packaging for RF/antenna systems
• Familiarity with RF performance considerations such as dielectric properties insertion loss and boresight error
• Strong background in structural and thermal analysis for extreme environments
• Proficiency in CAD and analysis tools (e.g. NX SolidWorks ANSYS or equivalent)
• Experience with tolerance stack-up alignment and precision assembly design
• Familiarity with materials used in RF applications (e.g. ceramics composites low-loss dielectrics) and high-temperature environments
• Government sites systems or information as determined by the Company and/or applicable U.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. 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.
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.