
Senior Manufacturing Engineer – Warhead Integration & Test
Required skills
- warhead
- integration
- test
- explosive loading
- fuze integration
- arming/safing mechanisms
- missile-interface mating
- non-destructive inspection
- leak testing
- electrical continuity
Nice to have
- DoD warhead programs
- hypersonic strike systems
- conventional munitions
- insensitive munitions
- IM
- shaped-charge
Role summary
Castelion is seeking a Senior Manufacturing Engineer with expertise in warhead integration and testing for explosive loading, fuze integration, and missile-interface mating. The role involves developing and executing integration and test plans, designing production tooling and automated systems, and implementing DFM, PFMEA, and SPC for high-yield manufacturing. Responsibilities include root-cause analysis of failures, authoring quality documentation compliant with AS9100 and MIL-STD-810, scaling production lines, and collaborating with suppliers on energetic materials. The position requires 7+ years of manufacturing engineering experience in aerospace/defense hardware, with 4+ years specifically supporting warhead or energetic systems integration and test. Experience with DoD warhead programs and ITAR regulations is preferred.
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
Basic Qualifications
Preferred Skills and Experience
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 hr@castelion.com. 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.
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