Tooling – Automation & Controls Manager

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.  

Manager, Tooling, Automation & Controls

We are seeking a Manager of Tooling, Automation & Controls to lead the design, development, deployment, and sustainment of advanced manufacturing tooling and automated systems for hypersonic missile production. This role owns the full lifecycle of custom tooling, fixtures, automated work cells, robotic systems, and industrial controls architectures supporting solid rocket motors, seekers, warheads, avionics, and vehicle integration. You will build and lead a high-performing team of tooling engineers, automation specialists, and controls engineers to deliver scalable, high-reliability manufacturing solutions that enable rapid iteration and high-rate production while meeting stringent DoD, AS9100, ITAR, and explosive-safety requirements.

Responsibilities

• Lead a multidisciplinary team responsible for all manufacturing tooling, automation, and controls across Castelion's production programs.
• Oversee the design and qualification of precision tooling and fixtures for composite filament winding, propellant casting, avionics integration, and final vehicle build.
• Architect and deploy automated manufacturing cells, robotic systems, and motion-control solutions for high-precision, hazardous, and high-volume processes.
• Direct controls system development (PLC, HMI, SCADA, motion control, safety PLC) with full compliance to functional safety and Class I Div 1 / hazardous location standards.
• Drive end-to-end project execution from concept through first article testing, commissioning, and production handover, managing budgets, and schedules.
• Champion Design for Manufacturability (DFM) and automation-first approaches in collaboration with design, manufacturing, and quality teams.
• Implement Industry 4.0 capabilities including MES integration, machine vision, digital twins, predictive maintenance, and real-time process monitoring.
• Establish and maintain standards for tooling design, controls architecture, documentation, and spare parts strategies to support 24/7 production operations.
• Manage vendor relationships for capital equipment, robotics, and controls hardware; negotiate contracts and lead equipment procurement.
• Mentor and develop engineers while fostering a culture of safety, innovation, and continuous improvement in a fast-paced defense environment.

Basic Qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Automation Engineering, or related field
• 5+ years in tooling, automation, and controls engineering for complex manufacturing.

Preferred Skills and Experience

• 10+ years in tooling, automation, and controls engineering for complex manufacturing.
• 5+ years in a leadership or people-management role.
• Strong background in aerospace, defense, or energetic materials production environments.
• Expert-level experience with industrial automation platforms (Rockwell, Beckhoff, Siemens), robotics (Fanuc, ABB, KUKA), and motion control systems.
• Proficient in 3D CAD (SolidWorks / NX), automation design software, EPLAN / AutoCAD Electrical, and simulation tools.
• Deep knowledge of PLC programming, industrial networking (EtherCAT, EtherNet/IP), machine vision, and safety-rated controls.
• Strong understanding of large-scale composite manufacturing, propellant handling, and precision electromechanical assembly tooling.
• Experience scaling automation from prototype to high-rate production.
• Leadership of tooling & automation programs for solid rocket motors, missiles, or hypersonic systems.
• Familiarity with ITAR, ATF, and DoD explosive safety standards.
• Proven people leadership and talent development skills.
• Strong project and program management capabilities with the ability to drive multiple parallel initiatives.
• Excellent communication and stakeholder management at all levels, including executive and customer presentations.
• Data-driven decision making and passion for building world-class manufacturing systems.

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.