Lead Integration & Test EngineerWe are seeking a Lead Integration & Test Engineer with deep expertise in the integration and verification of warhead systems into complete hypersonic missile vehicles. This role focuses on leading the safe and reliable integration of warheads (including energetics, fuzing, safe-and-arm devices, and structural interfaces) with missile airframes, radars, propulsion, avionics, and thermal protection systems. You will own end-to-end integration & test 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- Deliver a production ready integration & test process in Rio Rancho New Mexico
- Develop a plan to scale from low-rate initial production to full volume production supporting thousands of units per year
- Support a rapid test flight cadence to validate vehicle capability
- Develop safe integration and testing processes for the vehicle that ensure operator safety
- Build a world-class integration and test engineering team that can independently support future facility development and production execution
Key Responsibilities- Lead warhead-to-vehicle integration activities including mechanical mating, electrical interface verification, fuze/S&A installation, and safe separation testing.
- Develop and execute comprehensive vehicle-level Integration & Test 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 integration & test engineers and lead cross-functional I&T teams during build and test campaigns.
- Drive continuous improvement in integration processes, test automation, and digital thread implementation for faster iteration cycles.
Required QualificationsEducation:- Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, Systems Engineering, or related field.
Experience: - 8+ years 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.
Technical Skills- Strong experience with ordnance handling, safe-and-arm devices, and energetic materials integration.
- Proficiency in test automation (LabVIEW, Python, MATLAB), data acquisition systems, and telemetry.
- Hands-on with environmental testing and ordnance functional verification.
- Requirements management and configuration control.
- Familiarity with 3D CAD for integration planning.
Preferred Experience- 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.
Soft Skills- Proven ability to lead technical teams in high-stakes, safety-critical environments.
- Excellent communication and presentation skills for executive and customer briefings.
- Strong problem-solving under stringent safety and schedule constraints.
Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.
Other Duties Please 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. Duties, responsibilities and activities may change at any time with or without notice.
Additional Eligibility Requirements This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.
