Lead Manufacturing Engineer - Solid Rocket Motors

Why Castelion, Why Now 

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability. 

This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.  

About Castelion

Castelion is building affordable, rapidly producible hypersonic strike weapons for the U.S. military. We move quickly from design to flight test to production, and we are standing up R&D manufacturing at our facility in Midland, Texas.

Position Overview

We are seeking a Lead Manufacturing Engineer to own manufacturing processes and the team responsible for solid rocket motors at our Midland, Texas facility. This role focuses on developing, optimizing, qualifying, and executing energetic operations.  You will drive process improvements, lead prototype and research builds and ensure products are high quality and manufactured safely and efficiently. You will work closely with Design, Automation & Controls, Quality, Test, and fellow Manufacturing Engineers to ensure your products integrate with the larger system, and you will contribute to new product introduction, continuous improvement, and facility ramp-up at our Midland facility.

What You’ll Accomplish in Your First 12 Months

• Establish safe, repeatable manufacturing processes for solid rocket motors, with process specifications, work instructions, and explosives SOPs in place.

• Qualify the tooling, equipment, and processes needed for R&D and low-rate initial production to inform production-scale manufacturing.

• Execute R&D efforts to support the Blackbeard program. 

Key Responsibilities

• Own development and optimization of solid rocket motor manufacturing processes, including propellant mix and cast, motor integration, and igniter assembly.

• Drive Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, control plans, and statistical process control (SPC) to improve yield, reduce cycle time, and lower cost.

• Author explosives operating procedures (SOPs) and support process hazard analyses, hazard classification, and explosives site planning for new and modified operations.

• Implement electrostatic discharge (ESD) controls and safe handling practices for initiators, bridgewire devices, and other electrically sensitive components.

• Support equipment qualification and process validation at the Midland, TX facility 

• Interface with suppliers on materials, tooling, and equipment to resolve issues and improve incoming quality.

Required Qualifications

Education: Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Materials Science, or related field.

Experience:

• 2+ years of manufacturing  or mechanical engineering experience. Experience with energetic materials or solid rocket motors is a plus.

• Demonstrated success developing and scaling manufacturing processes from prototype to low-rate or rate production.

• Experience in fast-paced environments such as aerospace startups.

Technical Skills:

• Hands-on experience building, inspecting, and accepting assemblies

• Proficiency in CAD (SolidWorks or NX), GD&T, tooling/fixture design, process documentation, and nonconformance disposition.

• Working knowledge of explosives safety requirements, hazard analysis, and hazardous process manufacturing is a plus.

Eligibility:

• This position requires access to information and technology controlled under the International Traffic in Arms Regulations (ITAR). Applicants must be U.S. persons as defined under ITAR.

• Applicants must hold, or be able to obtain and maintain, a U.S. government security clearance.

Preferred Experience

• Experience with energetic material or solid rocket motor manufacturing

• Prior involvement in facility stand-up, equipment qualification, or production ramp activities.

• Experience supporting ITAR-controlled and classified programs.

What We’re Looking For

• A safety-first mindset with rigorous attention to detail in high-consequence energetic environments.

• A data-driven problem solver who is as comfortable on the production floor as at the desk.

• A clear communicator who collaborates across engineering, production, and manages multiple priorities in a fast-paced setting.

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. 

Affirmative Action/EEO Statement 

Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law. 

Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact [email protected]. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law. 

Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation. 

EAR/ITAR Requirements 

This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.