Hypersonic Warhead I&T Lead Engineer

Castelion Corporation; Torrance (CA); Hybrid; USD 140,000 - 190,000; Full time

Job summary

Castelion is seeking a Lead Integration & Test Engineer to own end-to-end integration and test strategies for warhead-vehicle systems in next-generation hypersonic missiles. You will lead cross-functional teams across design, manufacturing, propulsion, radar, and avionics to ensure safe, reliable formation of warheads with airframes and sensors.

This role requires 8+ years in aerospace integration and 4+ years with warheads or energetic systems, plus hands-on LabVIEW, Python, and MATLAB

Qualifications

• Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, Systems Engineering, or related field.
• 8+ years in integration and test for complex aerospace or defense systems.
• 4+ years specifically with warheads, munitions, or energetic systems integration.

Responsibilities

• Lead warhead-to-vehicle integration activities including mechanical mating, electrical interface verification, fuze/S&A installation, and safe separation testing.
• Develop and execute comprehensive vehicle-level Integration & Test plans covering functional checkout, ordnance arming sequences, environmental qualification, and system verification.
• Design and commission integration tooling, test fixtures, and automated test equipment for warhead handling and full missile assembly.
• Oversee environmental stress screening (thermal, vibration, shock, EMI/EMC) and functional performance testing of integrated warhead-vehicle systems.
• Support flight test preparation, range coordination, pre-flight checkout, and post-flight data analysis and anomaly resolution.
• Perform root-cause investigations and corrective actions for integration and test anomalies using FRACAS and fault tree analysis.
• Ensure full compliance with explosive safety standards, DoD 6055.09, MIL-STD-810, and mission assurance requirements.
• Mentor integration & test engineers and lead cross-functional I&T teams during build and test campaigns.
• Drive continuous improvement in integration processes, test automation, and digital thread implementation for faster iteration cycles.

Education

Aerospace/Mechanical/Systems Engineering degree

Leadership of vehicle-level integration projects

Strong analytical and problem-solving skills

Tools

LabVIEW

Python

MATLAB

3D CAD

Job description

Castelion is seeking a Lead Integration & Test Engineer to own end-to-end integration and test strategies for warhead-vehicle systems in next-generation hypersonic missiles. You will lead cross-functional teams across design, manufacturing, propulsion, radar, and avionics to ensure safe, reliable formation of warheads with airframes and sensors.

This role requires 8+ years in aerospace integration and 4+ years with warheads or energetic systems, plus hands-on LabVIEW, Python, and MATLAB