Senior Manufacturing Engineering- Contractor

Senior Manufacturing Engineer - Warhead Integration & Test

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.

Senior Manufacturing Engineer - Warhead Integration & Test

Castelion is seeking an experienced Materials & Process Engineer to serve as the company's 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.

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.
• Perform root-cause analysis and corrective actions for integration/test failures using 8D, fault-tree, and FRACAS methods; 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.
• 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.

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

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 View email address on click.appcast.io 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.

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