Aerospace Sheet Metal Forming & Welding Engineer

Castelion Corporation; Torrance (CA); On-site; USD 120,000 - 170,000; Full time

Job summary

Castelion Corporation in Torrance, CA seeks a Senior Manufacturing Engineer to own sheet metal forming and welding for solid rocket motor and hypersonic vehicle hardware. You will define forming methods, weld procedures, fixtures, and production flow to deliver flight-qualified components from development to production.

You will collaborate with Design, Quality, Tooling & Automation, and Operations to enable DFM/DFA, PFMEA, SPC, and robust qualification.

Qualifications

• Bachelor’s degree in Manufacturing, Mechanical, Welding, Materials Science, or related field.
• 6–10+ years of aerospace/defense manufacturing engineering experience.
• 3+ years owning sheet metal forming and welding on flight or mission-critical hardware.
• Proven success qualifying fabrication processes and transitioning to production.

Responsibilities

• Own manufacturing processes for sheet metal forming and welding, including cutting, bending, rolling, hydroforming or equivalent methods, fit-up, welding, post-weld processing, and final inspection.
• Develop and qualify weld procedures, forming processes, fixtures, and work instructions meeting dimensional, structural, and quality requirements.
• Execute DFM/DFA, PFMEA, control plans, and SPC to improve first-pass yield, cycle time, and cost.
• Define inspection and NDE strategies for formed and welded hardware (dimensional inspection, visual weld inspection, and approved NDE methods).
• Partner with Tooling, Automation & Controls on forming dies, weld fixtures, positioners, and robotic welding cells.
• Support new product introduction and design changes with producibility input on materials, bend radii, joint design, tolerances, and sequence.
• Lead root-cause analysis and corrective actions for forming defects, weld defects, distortion, fit-up issues, and dimensional escapes.
• Author and maintain travelers, WPS/PQR support documentation and quality records per AS9100 and customer requirements.
• Collaborate with suppliers on sheet stock, formed details, and welded subassemblies; drive incoming quality and process capability.
• Support equipment qualification and production ramp in Torrance, CA and the Project Ranger campus in New Mexico.

Skills

Sheet metal forming

Welding processes

DFM / DFA

PFMEA

SPC

CAD: SolidWorks

CAD: NX

Fixture concepting

Education

Bachelor’s degree in Manufacturing/Mechanical/Welding Engineering or related field

Tools

SolidWorks

NX

Welding equipment & qualification tools

Job description

Castelion Corporation in Torrance, CA seeks a Senior Manufacturing Engineer to own sheet metal forming and welding for solid rocket motor and hypersonic vehicle hardware. You will define forming methods, weld procedures, fixtures, and production flow to deliver flight-qualified components from development to production.

You will collaborate with Design, Quality, Tooling & Automation, and Operations to enable DFM/DFA, PFMEA, SPC, and robust qualification.