About CastelionCastelion is bringing a new approach to defense development and production: short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production at scale. The company is designing, building, and testing next-generation long-range strike weapons systems to give America and its allies a definitive edge and deter future conflicts.
The Opportunity
Castelion is looking for a Lead Integration & Test Engineer with deep expertise in the integration and verification of warhead systems into complete hypersonic missile vehicles. You will own end-to-end I&T strategies from subassembly through full vehicle level, supporting ground qualification, environmental testing, and flight test campaigns for next-generation hypersonic strike weapons.
You will serve as the technical authority on warhead-vehicle integration and test, collaborating closely with design, manufacturing, propulsion, radar, quality, and mission assurance teams to meet stringent DoD standards and mission requirements. Key outcomes for 2026 include delivering a production-ready I&T process in Rio Rancho, New Mexico; developing a scale plan from LRIP to thousands of units per year; supporting a rapid flight test cadence; and building the integration and test engineering team that can independently support future facility development and production execution.
What You'll Do
- • Lead warhead-to-vehicle integration activities including mechanical mating, electrical interface verification, fuze and S&A installation, and safe separation testing
- • Develop and execute comprehensive vehicle-level I&T plans covering functional checkout, ordnance arming sequences, environmental qualification, and system verification
- • Design and commission integration tooling, test fixtures, and automated test equipment for warhead handling and full missile assembly
- • Oversee environmental stress screening (thermal, vibration, shock, EMI/EMC) and functional performance testing of integrated warhead-vehicle systems
- • Support flight test preparation, range coordination, pre-flight checkout, and post-flight data analysis and anomaly resolution
- • Perform root-cause investigations and corrective actions for integration and test anomalies using FRACAS and fault tree analysis
- • Ensure full compliance with explosive safety standards, DoD 6055.09, MIL-STD-810, and mission assurance requirements
- • Mentor I&T engineers and lead cross-functional teams during build and test campaigns
- • Drive continuous improvement in integration processes, test automation, and digital thread implementation for faster iteration cycles
You Should Have
- • 8+ years of experience in integration and test for complex aerospace or defense systems
- • 4+ years specifically working with warheads, munitions, or energetic systems integration
- • Demonstrated leadership of vehicle-level integration and test campaigns, preferably on missile or hypersonic programs
- • Strong experience with ordnance handling, safe-and-arm devices, and energetic materials integration
- • Proficiency in test automation using LabVIEW, Python, or MATLAB, plus data acquisition systems and telemetry
- • Hands-on experience with environmental testing and ordnance functional verification
- • Experience with requirements management, configuration control, and 3D CAD for integration planning
- • U.S. citizenship or permanent resident status required (ITAR)
- • Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, Systems Engineering, or a related field
Nice to Have
- • Direct experience on DoD missile or hypersonic warhead programs
- • Background in fast-paced development environments
- • Knowledge of insensitive munitions and advanced warhead designs
- • Prior flight test support at ranges
- • Experience with classified programs and TS/SCI level work
Compensation and Benefits
Long-term stock incentives for all employees. Comprehensive medical, vision, and dental insurance, plus four weeks of paid time off per year.