Materials Engineer - Flight Vehicle Support

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.  

Materials Engineer – Flight Vehicle Support

Castelion is seeking a highly motivated Junior Materials & Processes (M&P) Engineer to support the development, qualification, and production of advanced materials for hypersonic flight applications. This role will focus on adhesive bond development, mechanical testing, materials characterization, and engineering documentation in support of solid rocket motors and other flight hardware.

The successful candidate will work closely with senior engineers to execute laboratory testing, analyze material performance, generate technical documentation, and support material qualification activities. This position requires strong attention to detail, hands-on laboratory skills, and a desire to develop expertise across a broad range of aerospace materials and manufacturing processes.

Responsibilities

• Prepare and test adhesive bond specimens in accordance with internal procedures and applicable ASTM standards.

• Perform materials characterization and mechanical testing in support of flight hardware and thermal protection system (TPS) development programs.

• Analyze experimental data and prepare technical reports summarizing results and recommendations.

• Generate and maintain engineering documentation including material specifications, process specifications, test plans, qualification reports, and test procedures.

• Support material failure investigations and root cause analyses.

• Work closely with design, manufacturing, and quality teams to support material selection, qualification, and production activities.

Basic Qualifications

• Bachelor's degree in Materials Science & Engineering, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, or a related discipline.

Preferred Skills and Experience

• 0–3 years of engineering experience (internships or undergraduate research considered).

• Strong analytical and problem-solving skills.

• Excellent written and verbal communication skills.

• Ability to work effectively in both laboratory and cross-functional engineering environments.

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.