Senior Composites R&D Technician – Layup

Castelion is seeking a Sr. Composites R&D Technician to own and advance layup processes for high-temperature composite structures. This role is hands-on and central to developing scalable manufacturing approaches for advanced materials, including ceramic matrix composites (CMCs).

You will serve as a technical anchor on the shop floor—driving process development, executing builds, and establishing best practices that enable consistent, repeatable production.

Responsibilities

• Develop and refine layup processes for high-temperature composite materials, including prepreg-based CMC panels
• Execute hands-on layup, molding, and fabrication activities to support rapid development and testing
• Establish and maintain standards for consumables, layup techniques, and shop processes
• Support tooling design and fabrication for composite part production
• Partner with engineering to iterate on materials and process development
• Document processes and ensure repeatability as production scales

Basic Qualifications

• 5+ years of experience in composites layup, ideally in aerospace or high-performance applications
• Experience with high-temperature composite materials
• Hands-on expertise with prepreg layup processes
• Familiarity with press molding and/or filament winding
• Experience supporting or developing manufacturing processes

Preferred Skills and Experience

• Experience with ceramic matrix composites (CMCs)
• Background in tool making for composite parts
• Experience in R&D or early-stage manufacturing environments
• Ability to operate independently in a fast-paced, low-structure setting

Leadership Qualities

Bias to Action and Creative Problem Solving. Desire and experience questioning assumptions in ways that lead to break through ideas that are ultimately implemented. Successfully bring in applicable processes/concepts/materials from other industries to achieve efficiency gains. Ability to personally resolve minor issues in development without requiring significant support.

High Commitment, High Initiative. A successful candidate will have a genuine passion for Castelion's mission and consistently look for ways to contribute to the company's technical goals and prevent hardware blockers. Ability to work in a fast paced, autonomously driven, and demanding atmosphere. Strong sense of accountability and integrity.

Clear Communicator. Proactively communicates blockers. Trusted in previous roles to be voice of company with regulators, suppliers, gate keepers and customers. Capable of tactfully managing relationships with stakeholders to achieve company-desired outcomes without compromising relationships. Emails, IMs and verbal interactions are logical, drive clarity, and detailed enough to eliminate ambiguity.