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

• Lead warhead assembly, integration, and functional test processes for explosive loading, fuze integration, arming/safing mechanisms, and missile-interface mating.

• Develop and execute comprehensive integration & test plans covering component-level, subassembly, and full-warhead verification (including non-destructive inspection, leak testing, electrical continuity, and safe-arm validation).

• Design and qualify production tooling, fixtures, automated work cells, and test stands for precision explosive handling, potting, and environmental stress screening.

• Execute Design for Manufacturability (DFM), PFMEA, control plans, and statistical process control (SPC) to drive first-pass yield >98% and cycle-time reduction.

• Perform root-cause analysis and corrective actions for integration/test failures using 8D, fault-tree, and FRACAS methods; support MRB/FRB and explosive safety reviews.

• Author and maintain manufacturing work instructions, test procedures, travelers, and quality records compliant with AS9100, MIL-STD-810, and customer requirements.

• Scale production lines from prototype to high-rate manufacturing, including capacity modeling, facility layout, and cost-reduction initiatives.

• Collaborate with suppliers on energetic materials and fuze components; implement incoming inspection and supplier quality improvements.

• Drive continuous improvement and technology insertion to support next-generation hypersonic warhead programs.

Basic Qualifications

• Bachelors degree in Manufacturing Engineering, Mechanical Engineering, Materials Science, or related field.
• 7+ years in manufacturing engineering for complex aerospace or defense hardware.

• 4+ years specifically supporting warhead, munitions, or energetic-systems integration and test (or equivalent high-reliability explosive assembly).

• Proven success transitioning warhead or ordnance hardware from prototype through LRIP to full-rate production.

Preferred Skills and Experience

• Direct work on DoD warhead programs, hypersonic strike systems, or conventional munitions.

• Experience in fast-paced defense environments.

• Background with insensitive munitions (IM), shaped-charge, or multi-mode warhead designs.

• Familiarity with ITAR-controlled programs, ATF regulations, and classified manufacturing protocols.

Additional Requirements

• Must be willing to work extended hours and/or weekends as needed
• Must be able to travel up to 20%

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.