Manufacturing Engineer, HarnessingCastelion is seeking a Manufacturing Engineer to lead the development and implementation of manufacturing processes for wiring harnesses, cable assemblies, interconnect systems, and associated test plans. This role will support both in-house and supplier fabrication and test activities as we transition designs from prototype to scaled production in support of next-generation defense systems.
Key Outcomes for 2026- Establish In-House Harness Fabrication Capability - define, document, and implement procedures, tooling standards, work instructions, and process flows for harness fabrication and validation.
- Establish & Qualify a Supply Chain for Prototype and Production Harness Fabrication - identify, evaluate, and onboard supplier partners for harness fabrication and test that align with part complexity, lead time needs, and quality/risk requirements. Define supplier qualification criteria (capability matrices, certifications, workmanship standards, test coverage, inspection tools) and establish supplier audits, capability studies, and baseline process validations.
- Deliver All Harness Assemblies On-Time with Zero Defects - drive, track, and report build execution for all harnessing to meet development, test, and qualification milestones. Establish and enforce key quality checkpoints to detect and resolve assembly, continuity, or functional defects before delivery to integration.
Responsibilities- Assembly & Test Procedure - create and maintain work instructions, bill of materials (BOM/MBOM), harness assembly flows, test plans, fixture/tooling specifications, and manufacturing process documentation for prototype and production harness builds.
- Supplier Development & Support - partner with supply chain to qualify and develop external harness fabrication partners, define quality/test criteria (continuity, insulation, functional, hi-pot), and support supplier readiness for production builds.
- Prototype to Production Transition - support design reviews with a focus on design for manufacturability (DFM), design for test (DFT), connector selection, harness routing, and supplier handoff readiness. Facilitate risk analysis and manufacturing readiness reviews (MRRs).
- Testing & Validation - develop and implement harness test procedures and systems for continuity, insulation resistance, high-pot/functional verification, environmental screening when required, and test data analysis.
- Continuous Improvement & Metrics - drive yield improvement, throughput gains, defect reduction, and cost optimization through Lean and CI methodologies.
Requirements & Qualifications- Bachelors degree in mechanical, Electrical, Manufacturing, or related Engineering discipline.
- 3+ years of experience in manufacturing engineering with emphasis on wiring harness/cable assembly processes, fabrication, and test.
- Strong familiarity with harness standards (crimping, routing, strain relief techniques), electrical continuity/functional test methods, and assembly best practices.
- Hands-on experience developing manufacturing processes and work instructions for electromechanical hardware.
- Excellent written and verbal communication skills.
- Must be authorized to work in the U.S. and comply with ITAR eligibility requirements.
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.
