Senior Manufacturing Engineer

About Castelion

Castelion is developing and delivering advanced defense systems at a time when execution matters more than ever. The company believes focus and technical excellence are decisive advantages — and is building a team that can deliver real capability, not just concepts.

This is an early-stage opportunity where your work will directly shape critical systems, influence major technical decisions, and have immediate real-world impact.

The Opportunity

Castelion is looking for a Senior Manufacturing Engineer to support the development and build of critical components and subsystems for long-range hypersonic strike vehicles. The primary focus of the role is helping establish a production-ready separation assembly line by early 2027, scaling from development builds to production rates of thousands of units per year.

You will work closely with engineering teams to execute complex builds, mature assembly and integration processes, and own the manufacturing infrastructure that turns advanced defense technology into deliverable hardware.

What You'll Do

• •      Lead day-to-day production of mechanisms including the Castelion separation system and launchers
• •      Develop process and factory design to transition from development to production rates of thousands of units per year
• •      Develop and refine process documentation including build instructions, test procedures, safety standards, and mBOMs
• •      Create, maintain, and communicate detailed plans and schedules
• •      Work closely with supply chain to develop new and existing suppliers
• •      Design and validate tooling
• •      Participate in design reviews to drive design for manufacturing (DFM)

You Should Have

• •      5+ years of manufacturing engineering experience for high-performance aerospace products
• •      Bachelor's degree in an engineering discipline
• •      2+ years of hands-on manufacturing, fabrication, assembly, or testing experience
• •      Willingness to work extended hours or weekends as needed and travel up to 30%
• •      Ability to lift more than 50 lbs

Nice to Have

• •      Experience in aerospace mechanisms
• •      Experience with structural welding
• •      Experience with ordnance
• •      Experience with NX/Teamcenter CAD/PDM
• •      Hands-on experience in metal fabrication
• •      Experience transitioning development processes to production

Compensation and Benefits

Meaningful equity for all full-time employees, with share value that has increased 150x over three years.

Benefits include 100% employer-covered medical premiums for employees (80% for dependents); 90% employer-covered dental and vision (80% for dependents); FSA and HSA options; 401k; four weeks of paid time off; ten company-paid holidays; up to 10 weeks of paid parental leave for birthing parents and 4 weeks for non-birthing parents; $100 monthly fitness stipend; catered lunches and team meals; fully stocked kitchen; and onsite EV charging.