Castelion

Overview

Castelion is rapidly developing advanced defense systems and is seeking a Senior Manufacturing Engineer to manage sheet metal forming and welding processes for solid rocket motor and hypersonic vehicle hardware. This role involves significant ownership and collaboration with various teams to ensure high-quality production.

Responsibilities

• Own manufacturing processes for sheet metal forming and welding.
• Develop and qualify weld procedures, forming processes, fixtures, and work instructions.
• Execute DFM/DFA, PFMEA, control plans, and statistical process control to improve yield and cost.
• Define inspection and NDE strategies for formed and welded hardware.
• Partner with Tooling, Automation & Controls on forming dies and weld fixtures.
• Support new product introduction and design changes with producibility input.
• Lead root-cause analysis and corrective actions for defects.
• Author and maintain travelers and quality records compliant with AS9100.
• Collaborate with suppliers on sheet stock and welded subassemblies.
• Support equipment qualification and production ramp in Torrance, CA and New Mexico.

Requirements

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
• 6–10+ years of manufacturing engineering experience in aerospace, defense, or high-reliability metallic fabrication.
• 3+ years of hands-on ownership of sheet metal forming and welding processes.
• Strong practical knowledge of sheet metal forming and fusion welding processes.
• Proficiency in CAD (SolidWorks or NX), GD&T, tolerance stack-up, and fixture concepting.
• Working knowledge of weld procedure development and distortion control.
• Experience with PFMEA, SPC, and root-cause methods.
• Familiarity with metrology and NDE of formed and welded structures.
• Ability to write clear work instructions.

Additional Information

• This position may require access to classified information or restricted U.S. Government sites.
• Castelion is an Equal Opportunity Employer.