Manufacturing Engineer - Motors, Lead
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.
Lead Manufacturing Engineer - Motors
Castelion is seeking a Lead Manufacturing Engineer to own all aspects of solid rocket motor production. In this role, you will lead a cross-functional team responsible for the safe, repeatable, and rate-capable manufacture of solid propellant motors, from propellant mixing through final acceptance. You will drive aggressive cost, quality, schedule, and safety targets in an energetics manufacturing environment while scaling production for mission-critical programs.
CORE RESPONSIBILITIES
Manufacturing Leadership and Execution. Lead a team of manufacturing engineers in the daily execution of solid rocket motor production, including propellant mixing, casting, case bonding, and proof/acceptance testing. Ensure on-time delivery of flight hardware while maintaining zero safety incidents and full compliance with DoD regulations.
Process Ownership and Continuous Improvement. Own the entire solid motor manufacturing value stream. Develop, qualify, and continuously improve processes, tooling, and facilities to increase throughput, reduce labor hours, and achieve first-pass yield targets. Implement automation, digital thread/MES, and advanced inspection techniques to support rapid production scaling.
Technical Authority and Customer Interface. Serve as the primary technical interface to Design Engineering, Program Management, Quality, EHS, and the customer on producibility, non-conformances, and anomaly resolution. Lead root-cause and drive robust corrective actions for defects or process escapes.
New Product Introduction and Capacity Expansion. Lead manufacturing readiness for new solid motor designs, including process development, PFMEA, control plans, and qualification builds. Plan and execute capital projects for the installation of mixers, casting facilities, and automated insulation/liner application.
Safety and Regulatory Compliance. Enforce strict adherence to energetic materials safety standards (NFPA 495, DOD 4145.26M). Author and maintain explosive safety submissions, hazard analyses, and operating procedures. Champion a strong safety culture across the team.
Team Development. Mentor junior engineers and technicians, conduct performance reviews, and build succession plans. Foster a culture of ownership, urgency, and technical excellence.
Basic Requirements
- Bachelors degree in Mechanical, Aerospace, Chemical, or Manufacturing Engineering.
- Minimum of 7 years of hands-on experience in an aerospace manufacturing environment or equivalent.
- At least 3 years in formal leadership.
Preferred Experience
- Proven track record leading production of solid rock motors from development through sustained rate production.
- Deep expertise in propellant formulation, vacuum casting, case-bonded grain design, liner/insulator systems, and non-destructive evaluation of energetic articles.
- Demonstrated success scaling hazardous processes while reducing cost per pound and labor hours per motor.
- Prior work on orbital launch vehicles, strategic systems, missile defense, or hypersonic programs.
- Aptitude for mentoring teams and influencing cross-functional stakeholders in a fast-paced, resource-constrained startup 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 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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