Materials & Process Engineer, Densification

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.

Materials & Process Engineer, Densification Castelion is seeking a highly motivated recent graduate or early-career engineer to support R&D development and scale-up of our ceramic matrix composite (CMC) fabrication and densification processes. This role will support the conversion of composite prepreg into finished high-performance thermal protection system (TPS) components. The position is ideal for a recent graduate interested in ceramic matrix composite processing and scaling manufacturing processes for high-performance aerospace hardware. The engineer will perform hands-on composite fabrication while supporting process development, characterization, and production scale-up.

Key processes include prepreg layup and forming, compression molding, curing, resin infiltration, and high-temperature pyrolysis. The engineer will characterize fabricated materials, own process data collection and analysis, and drive improvements in process repeatability and manufacturing readiness across the pilot line. Responsibilities Support composite layup, forming, and densification operations for CMC components. Execute compression molding, curing, resin infiltration, and high-temperature pyrolysis processes. Own process QA data collection, analysis, and database management. Characterize finished C/SiC materials to assess performance and guide process development.

Develop and optimize fabrication and densification parameters to improve material quality and process repeatability. Develop and maintain process documentation, work instructions, and standardized operating procedures. Support installation, maintenance, and scale-up of pilot-line manufacturing hardware.

Basic Qualifications

Bachelor's or Master's degree in Materials Science, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, or related field. Familiarity with composite processing and/or materials characterization techniques. Must be willing to work weekends when necessary. Ability to work independently in a hands-on engineering 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 [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.