Avionics Manufacturing Engineer - Electrical Integration

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.  

Avionics Manufacturing Engineer, Electrical Integration

Castelion is looking for an Avionics Manufacturing Engineer, Electrical Integration, reporting to the Lead Manufacturing Engineer of Avionics, to support the development and production of systems required for long-range hypersonic strike vehicles. This full-time position may be located at either our Allen, Texas, or Torrance, California facility.

As an Avionics Manufacturing Engineer focused on Electrical Integration, you will develop and improve the manufacturing processes used to integrate complex printed circuit board assemblies, electrical components, and interconnects into mechanical housings and higher-level avionics assemblies.

This role requires an understanding of electrical hardware, mechanical assembly, and manufacturing process control. You will write the work instructions and establish the process controls required to ensure avionics assemblies are built safely, correctly, and repeatably. You will also partner with other engineering teams to support the development of tooling, automation, inspection methods, and production testing.

The ideal candidate is comfortable working directly with flight hardware and can translate electrical, mechanical, thermal, and environmental requirements into practical manufacturing processes.

Responsibilities

• Develop and improve manufacturing processes for integrating PCBAs and electrical components into mechanical housings and higher-level avionics assemblies
• Write clear work instructions, visual aids, assembly procedures, and inspection criteria for avionics hardware
• Establish process controls for the installation of PCBAs, thermal interface materials, gaskets, fasteners, connectors, grounding features, and electrical interconnects
• Define and validate critical assembly parameters, including material placement, surface preparation, fastener torque, tightening sequence, compression, alignment, and cleanliness
• Partner with Design, Test, and Manufacturing Engineering to support the development of tooling, fixtures, automation, inspection methods, and production test equipment
• Review electrical schematics, PCBA drawings, mechanical drawings, bills of material, and assembly documentation to determine manufacturing requirements
• Provide manufacturability feedback related to assembly sequence, component access, connector routing, grounding, thermal management, tolerance stack-up, tooling access, and test access
• Troubleshoot electrical and electro-mechanical assembly issues and support root-cause investigations and corrective actions
• Support technicians during development and production builds and provide training on new or improved manufacturing processes
• Support the transition of avionics hardware from development builds into controlled, repeatable production
• Partner with Design Engineering, Test Engineering, Quality, Planning, Supply Chain, and Production to resolve manufacturing issues
• Improve first-pass yield, assembly time, workmanship, production flow, and process repeatability

Basic Qualifications

• Bachelor's degree in electrical, mechanical, manufacturing, aerospace engineering, or a related technical field
• 3+ years of experience in avionics, electronics, electrical integration, electro-mechanical assembly, or high-reliability manufacturing
• Hands-on experience integrating PCBAs or electrical components into mechanical assemblies
• Experience developing manufacturing processes, work instructions, inspection criteria, or process controls
• Ability to read electrical schematics, PCBA drawings, mechanical drawings, and manufacturing documentation
• Strong hands-on troubleshooting, communication, and technical problem-solving skills
• Must be willing to work extended hours and/or weekends as needed
• Must be able to travel up to 25% of the time

Preferred Skills and Experience

• Experience manufacturing or integrating flight avionics, defense electronics, automotive electronics, or other high-reliability hardware
• Experience with thermal interface materials, gap fillers, thermal pads, adhesives, gaskets, environmental seals, fasteners, and grounding features
• Experience supporting the development of manufacturing tooling, fixtures, automation, or production test equipment
• Experience with process validation and manufacturing acceptance criteria
• Familiarity with GD&T, tolerance stack-ups, mechanical fits, fastener torque, and electro[1]mechanical assembly processes
• Experience with electrical continuity, grounding, hipot, insulation resistance, or functional testing
• Working knowledge of IPC-A-610, IPC/WHMA-A-620, or similar workmanship standards
• Experience supporting both development and production hardware in a fast-paced aerospace or defense environment

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.