Senior Avionics Manufacturing Engineer (Hypersonic)

Castelion; Allen (TX); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Employee equity

Four weeks paid time off

Health insurance

401k plan

Parental leave

Meals provided

Fitness stipend

EV charging

Job summary

Castelion is seeking a Senior Manufacturing Engineer to lead the development and optimization of avionics electromechanical assembly for high-reliability defense electronics. The role focuses on transforming prototypes into scalable, high-yield production capable of meeting DoD, AS9100, and IPC standards.

You will own process development for PCBA integration, wire harness routing, enclosures, and related testing, and collaborate with design, quality, and supply chain teams to drive cost and

Qualifications

• Bachelor’s degree in a related field required.
• 7+ years in manufacturing engineering for complex aerospace or defense electronics hardware.
• 4+ years specifically supporting avionics or electromechanical assembly and integration.

Responsibilities

• Lead manufacturing process development for avionics electromechanical assembly.
• Design and qualify production tooling, fixtures, automated work cells, and test equipment.
• Execute DFM, DFA, PFMEA, and control plans to drive first-pass yield and cycle-time reduction.
• Establish SPC and metrology strategies for critical avionics parameters.
• Scale production from LRIP to full-rate manufacturing and optimize capacity.

Skills

7+ years manufacturing engineering

4+ years avionics assembly

3D CAD (SolidWorks or NX)

GD&T (ASME Y14.5)

ERP/MES systems

Education

Bachelor’s in Manufacturing/Mechanical/Electrical Engineering

Job description

Castelion is seeking a Senior Manufacturing Engineer to lead the development and optimization of avionics electromechanical assembly for high-reliability defense electronics. The role focuses on transforming prototypes into scalable, high-yield production capable of meeting DoD, AS9100, and IPC standards.

You will own process development for PCBA integration, wire harness routing, enclosures, and related testing, and collaborate with design, quality, and supply chain teams to drive cost and