Senior Avionics Manufacturing Engineer - High-Reliability

Castelion; Torrance (CA); On-site; USD 140,000 - 190,000; Full time

Benefits offered by this job

Employee equity

Paid parental leave

Meals & catering

Snacks & beverages

Fitness stipend

EV charging on site

Retirement plan

Job summary

Castelion is recruiting a Senior Manufacturing Engineer to lead avionics electromechanical assembly process development and scale production for demanding defense aerospace programs. You will own DFx, tooling, and inspection strategies, ensuring high yield and rigorous reliability.

You will collaborate across design, test, quality, and supply chain to transition from prototype to full-rate production while meeting DoD and AS9100 standards.

Qualifications

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

Responsibilities

• 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 SPC, in-process inspection, and metrology strategies for critical avionics parameters.
• 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 and related 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 programs.

Skills

3D CAD

GD&T

DFM/DFX

Root cause analysis

Automation experience

Education

Bachelor's in Engineering

Tools

ERP/MES

Job description

Castelion is recruiting a Senior Manufacturing Engineer to lead avionics electromechanical assembly process development and scale production for demanding defense aerospace programs. You will own DFx, tooling, and inspection strategies, ensuring high yield and rigorous reliability.

You will collaborate across design, test, quality, and supply chain to transition from prototype to full-rate production while meeting DoD and AS9100 standards.