Senior Avionics Manufacturing Engineer – High-Rel

Castelion Corporation; Allen (TX); Sur place; USD 120 000 - 150 000; Plein temps

Avantages offerts par ce poste

Equity for employees

4 weeks PTO

Medical coverage 100% employee

Dental & Vision coverage

401k plan

Parental leave

Meals & snacks provided

EV charging on site

Résumé du poste

Castelion Corporation in Texas seeks a Senior Manufacturing Engineer with deep expertise in avionics electro-mechanical assembly to develop, optimize, and scale manufacturing for PCBA, wire harnesses, enclosures, sensors, actuators, and subassemblies used in hypersonic missile systems.

You will collaborate with design, integration & test, quality, supply chain and automation teams to transition avionics from prototype to high-rate production while meeting strict DoD, AS9100, IPC and reliability

Qualifications

• 7+ years in manufacturing engineering for complex aerospace or defense electronics hardware.
• 4+ years specifically supporting avionics or electromechanical assembly and integration (high-reliability electronics preferred).
• Proven success transitioning avionics hardware from prototype through LRIP to full-rate production.
• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, or related field.

Responsabilités

• Lead manufacturing process development for avionics electromechanical assembly, including PCBA integration, conformal coating, potting, wire harness routing, connector termination, and enclosure sealing.
• Design and qualify production tooling, fixtures, automated work cells, and test equipment for precision electromechanical build and functional verification.
• Execute Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, and control plans to drive first-pass yield >95% and aggressive cycle-time reduction.
• Establish statistical process control (SPC), in-process inspection, and metrology strategies for critical avionics parameters (torque, continuity, insulation resistance, leak testing).
• Scale production from LRIP to full-rate manufacturing, including line balancing, capacity modeling, and cost-reduction initiatives.
• Perform root-cause analysis and corrective actions for assembly defects using 8D, fishbone, and fault-tree methods; support MRB/FRB dispositions.
• Author and maintain detailed work instructions, travelers, and quality records compliant with customer requirements.
• Collaborate with suppliers on incoming material qualification for PCBs, connectors, and electromechanical components.
• Drive continuous improvement projects targeting cost, quality, and throughput for next-generation hypersonic avionics programs.

Connaissances

3D CAD

GD&T

Tolerance analysis

Soldering

Crimping

Potting

Adhesive bonding

Cleanroom/ESD

ERP/MES

ESS/Vibration

Functional test

Automation

Formation

Bachelor's degree

Outils

SolidWorks

NX

Description du poste

Castelion Corporation in Texas seeks a Senior Manufacturing Engineer with deep expertise in avionics electro-mechanical assembly to develop, optimize, and scale manufacturing for PCBA, wire harnesses, enclosures, sensors, actuators, and subassemblies used in hypersonic missile systems.

You will collaborate with design, integration & test, quality, supply chain and automation teams to transition avionics from prototype to high-rate production while meeting strict DoD, AS9100, IPC and reliability