Senior Manufacturing Engineer - Warhead Integration & TestCastelion 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.
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.
