Senior Avionics Manufacturing Engineer, Hypersonic Radar

Castelion; Rio Rancho (NM); On-site; USD 120,000 - 170,000; Full time

Benefits offered by this job

Benefits package

Job summary

Castelion seeks a Senior Manufacturing Engineer with deep expertise in the high‑reliability assembly and integration of avionics and electromechanical systems for hypersonic missile vehicles. You will develop, optimize, and scale manufacturing processes for PCBA, wire harnesses, enclosures, sensors, actuators, and subassemblies to achieve high yield.

You will partner with design, integration & test, quality, supply chain, and automation teams to transition from prototype to LRIP and full‑rate

Qualifications

• Bachelor's degree in manufacturing, mechanical, electrical engineering or related field.
• 7+ years in manufacturing engineering for complex aerospace or defense electronics hardware.
• 4+ years supporting avionics or electromechanical assembly and integration.
• Proven success transitioning avionics hardware from prototype 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.
• Execute DFM, DFA, PFMEA, and control plans to drive first‑pass yield >95% and reduce cycle time.
• Establish SPC, in‑process inspection, and metrology strategies for avionics parameters.
• Scale production from LRIP to full‑rate manufacturing, including line balancing and capacity modeling.
• Perform root‑cause analysis with 8D/fishbone/fault‑tree; support MRB/FRB dispositions.
• Maintain work instructions, travelers, and quality records; collaborate with suppliers on incoming material qualification.
• Drive continuous improvement projects targeting cost, quality, and throughput for next‑gen programs.

Skills

3D CAD

GD&T

DFM/ DFA

SPC

Root-cause analysis

Lean / cost reduction

High-reliability avionics

Aerospace manufacturing

Education

Bachelor's degree in Manufacturing Engineering

Bachelor's in Mechanical/Electrical Engineering

Tools

SolidWorks

NX

ERP/MES

AS9100

Job description

Castelion seeks a Senior Manufacturing Engineer with deep expertise in the high‑reliability assembly and integration of avionics and electromechanical systems for hypersonic missile vehicles. You will develop, optimize, and scale manufacturing processes for PCBA, wire harnesses, enclosures, sensors, actuators, and subassemblies to achieve high yield.

You will partner with design, integration & test, quality, supply chain, and automation teams to transition from prototype to LRIP and full‑rate