Senior Manufacturing Engineer – Warhead Integration & Test

Role details

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.

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.

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 [email protected].

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.