Lead Integration & Test Engineer

Castelion; Torrance (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

Castelion in the United States is seeking a Lead Integration & Test Engineer to own end-to-end warhead-vehicle integration for hypersonic missile systems. You will lead subassembly through full vehicle level verification, driving safe, reliable integration with interfaces to airframes, radars, propulsion, avionics, and protection systems.

The role requires 8+ years in aerospace/defense integration, 4+ years with warheads or energetic systems, and strong leadership in I&T campaigns.

Qualifications

• 8+ years in integration and test for complex aerospace or defense systems.
• 4+ years with warheads, munitions, or energetic systems integration.
• Leadership of vehicle-level integration and test campaigns, preferably on missile or hypersonic programs.

Responsibilities

• Lead warhead-to-vehicle integration activities including mechanical mating, electrical interface verification, fuze/S&A installation, and safe separation testing.
• Develop and execute 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.

Skills

Integration & Test leadership

LabVIEW

Python

MATLAB

Test automation

Data acquisition

Telemetry

3D CAD

Education

Bachelor's in Aerospace Engineering

Master's in Mechanical/Systems Engineering

Tools

LabVIEW

Python

MATLAB

Job description

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.

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 Integration & Test Engineer

We are seeking a Lead Integration & Test Engineer with deep expertise in the integration and verification of warhead systems into complete hypersonic missile vehicles. This role focuses on leading the safe and reliable integration of warheads (including energetics, fuzing, safe-and-arm devices, and structural interfaces) with missile airframes, radars, propulsion, avionics, and thermal protection systems. You will own end-to-end integration & test strategies from subassembly through full vehicle level, supporting ground qualification, environmental testing, and flight test campaigns for next-generation hypersonic strike weapons. You will serve as the technical authority on warhead-vehicle integration and test, collaborating closely with design, manufacturing, propulsion, radar, quality, and mission assurance teams to meet stringent DoD standards and mission requirements.

Key Outcomes for 2026

• Deliver a production ready integration & test process in Rio Rancho New Mexico
• Develop a plan to scale from low-rate initial production to full volume production supporting thousands of units per year
• Support a rapid test flight cadence to validate vehicle capability
• Develop safe integration and testing processes for the vehicle that ensure operator safety
• Build a world-class integration and test engineering team that can independently support future facility development and production

Key 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

Required Qualifications

• Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, Systems Engineering, or related field.

Experience

• 8+ years in integration and test for complex aerospace or defense systems.
• 4+ years specifically working with warheads, munitions, or energetic systems integration.
• Demonstrated leadership of vehicle-level integration and test campaigns, preferably on missile or hypersonic programs.

Technical Skills

• Strong experience with ordnance handling, safe-and-arm devices, and energetic materials integration.
• Proficiency in test automation (LabVIEW, Python, MATLAB), data acquisition systems, and telemetry.
• Hands-on with environmental testing and ordnance functional verification.
• Requirements management and configuration control.
• Familiarity with 3D CAD for integration planning.

Preferred Experience

• Direct experience on DoD missile or hypersonic warhead programs.
• Background in fast-paced development environments
• Knowledge of insensitive munitions and advanced warhead designs.
• Prior flight test support at ranges
• Experience with classified programs and TS/SCI level work.

Soft Skills

• Proven ability to lead technical teams in high-stakes, safety-critical environments.