Senior Manufacturing Engineer, Radar
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.
Senior Manufacturing Engineer, Radar
We are seeking a Senior Manufacturing Engineer with deep expertise in the high-reliability assembly and integration of avionics and electromechanical systems for hypersonic missile vehicles. This role focuses on developing, optimizing, and scaling manufacturing processes for complex avionics hardware—including printed circuit board assemblies (PCBA), wire harnesses, electronic enclosures, sensors, actuators, connectors, and electromechanical subassemblies—to achieve repeatable, high-yield production.
You will serve as the technical authority on avionics electromechanical manufacturing, partnering with design, integration & test, quality, supply chain, and automation teams to transition advanced avionics from prototype to high-rate production while meeting stringent DoD, AS9100, IPC, and mission-critical reliability standards.
Responsibilities
- Lead manufacturing process development for avionics electromechanical assembly, including PCBA integration, conformal coating, potting, wire harness routing, connector termination, and enclosure sealing.
- Design and qualify production tooling, fixtures, automated work cells, and test equipment for precision electromechanical build and functional verification.
- Execute Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, and control plans to drive first-pass yield >95% and aggressive cycle-time reduction.
- Establish statistical process control (SPC), in-process inspection, and metrology strategies for critical avionics parameters (torque, continuity, insulation resistance, leak testing).
- Scale production from low-rate initial production (LRIP) to full-rate manufacturing, including line balancing, capacity modeling, and cost-reduction initiatives.
- Perform root-cause analysis and corrective actions for assembly defects using 8D, fishbone, and fault-tree methods; support MRB/FRB dispositions.
- Author and maintain detailed work instructions, travelers, and quality records compliant with customer requirements.
- Collaborate with suppliers on incoming material qualification for PCBs, connectors, and electromechanical components.
- Drive continuous improvement projects targeting cost, quality, and throughput for next-generation hypersonic avionics programs.
Basic Qualifications
- Bachelor's in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, or related field.
- 7+ years in manufacturing engineering for complex aerospace or defense electronics hardware.
- 4+ years specifically supporting avionics or electromechanical assembly and integration (high-reliability electronics preferred).
- Proven success transitioning avionics hardware from prototype through LRIP to full-rate production.
Preferred Skills and Experience
- Proficient with 3D CAD (SolidWorks or NX), GD&T (ASME Y14.5), and tolerance stack-up analysis.
- Strong experience in precision electromechanical assembly processes, including soldering, crimping, potting, adhesive bonding, and cleanroom/ESD protocols.
- Familiarity with ERP/MES systems and manufacturing execution for full aerospace traceability.
- Working knowledge of environmental stress screening (ESS), vibration, thermal cycling, and functional test integration for avionics.
- Direct work on missile, hypersonic, or high-reliability avionics systems for DoD programs.
- Experience in fast-paced defense or space environments (e.g., Anduril or SpaceX)
- Background with harsh-environment electronics (high-G, thermal extremes, radiation).
- Track record of implementing automation for electromechanical assembly and achieving significant cost or cycle-time reductions.
- Familiarity with ITAR-controlled programs 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.
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 hr@castelion.com. 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.
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