ResponsibilitiesDesign and develop RF-transparent structures, including radomes, windows, and associated support structures for high‑speed flight vehiclesLead the architecture and detailed design of RF subsystem packaging, including mounting, alignment, and environmental protection of antennas, seekers, and electronicsPerform structural and thermal analyses to ensure performance and reliability under extreme aerothermal, pressure, and dynamic environmentsWork closely with RF, avionics, materials, and thermal teams to ensure designs meet RF performance requirements such as transmission, reflection, boresight error while maintaining structural integrityDevelop and analyze interfaces between radomes, TPS, and primary structure, including sealing, attachment, and thermal isolation strategiesConduct tolerance analysis and assess alignment sensitivity and deformation impacts on RF performanceSupport prototyping, assembly, and hardware bring‑up, including troubleshooting and root‑cause analysis of structural and RF performance issuesDefine and execute qualification and environmental test plans, including thermal, vibration, and RF testingOptimize designs for mass, thermal performance, RF transparency, and manufacturabilityMentor junior engineers and contribute to best practices in RF structure and packaging designPartner closely with program leadership to make technical trades aligned with mission successBasic QualificationsBachelor's, Master's, or PhD in Mechanical Engineering or related field5+ years of experience in mechanical design for aerospace or high‑performance systemsExperience designing radomes, RF‑transparent structures, or packaging for RF/antenna systemsFamiliarity with RF performance considerations such as dielectric properties, insertion loss, and boresight errorStrong background in structural and thermal analysis for extreme environmentsProficiency in CAD and analysis tools such as NX, SolidWorks, ANSYS, or equivalentExperience with tolerance stack‑up, alignment, and precision assembly designFamiliarity with materials used in RF applications such as ceramics, composites, low‑loss dielectrics and high‑temperature environmentsExperience with hardware build, test, and troubleshooting in a lab or flight hardware environmentStrong problem‑solving mindset, thriving in a fast‑paced, hardware‑rich, high flight cadence environmentOther DutiesPlease 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. Senior Mechanical Design Engineer (RF Systems & Radomes)Job Openings Senior Mechanical Design Engineer (RF Systems & Radomes)About the jobCastelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever.