Senior Manufacturing Engineer, Radar

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

Senior Manufacturing Engineer – Avionics Electro-Mechanical Assembly

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.

This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.

We are seeking a Senior Manufacturing Engineer with deep expertise in the high-reliability assembly and integration of avionics and electromechanical systems for hypersonic missile vehicles. This role focuses on developing, optimizing, and scaling manufacturing processes for complex avionics hardware—including printed circuit board assemblies (PCBA), wire harnesses, electronic enclosures, sensors, actuators, connectors, and electromechanical subassemblies—to achieve repeatable, high-yield production.

You will serve as the technical authority on avionics electromechanical manufacturing, partnering with design, integration & test, quality, supply chain, and automation teams to transition advanced avionics from prototype to high-rate production while meeting stringent DoD, AS9100, IPC, and mission-critical reliability standards.

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 statistical process control (SPC), in-process inspection, and metrology strategies for critical avionics parameters (torque, continuity, insulation resistance, leak testing).
• Scale production from low-rate initial production (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.

Basic 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 (high-reliability electronics preferred).
• Proven success transitioning avionics hardware from prototype through LRIP to full-rate production.

Preferred Skills and Experience

• Proficient with 3D CAD (SolidWorks or NX), GD&T (ASME Y14.5), and tolerance stack-up analysis.
• Strong experience in precision electromechanical assembly processes, including soldering, crimping, potting, adhesive bonding, and cleanroom/ESD protocols.
• Familiarity with ERP/MES systems and manufacturing execution for full aerospace traceability.
• Working knowledge of environmental stress screening (ESS), vibration, thermal cycling, and functional test integration for avionics.
• Direct work on missile, hypersonic, or high-reliability avionics systems for DoD programs.
• Experience in fast-paced defense or space environments (e.g., Anduril or SpaceX)
• Background with harsh-environment electronics (high-G, thermal extremes, radiation).
• Track record of implementing automation for electromechanical assembly and achieving significant cost or cycle-time reductions.
• Familiarity with ITAR-controlled programs and classified manufacturing protocols.
• Employee Equity: Meaningful equity for all full-time employees - share value has increased 150x in three years
• Personal Time Off: Four (4) weeks of paid time off to unplug, reset, and come back sharp—velocity matters, burnout doesn’t
• Medical: We offer plans at 100% employee covered and 80% of dependent coverage
• Dental & Vision: We cover 90% employees and 80% for dependents to ensure you and your family have access to quality preventive and ongoing care
• FSA/HSA: To support long-term health and financial resilience, we offer FSA and HSA options that allow employees to set aside pre-tax dollars for eligible medical and dependent care expenses
• Retirement: 401k plan offered to support long term financial growth along side high-impact, high-velocity work
• Paid Parental Leave: We support growing families with meaningful time to bond and recover. Birthing parents are eligible for up to 10 weeks of paid leave, while non-birthing parents may take up to 4 weeks of paid leave. This time can be used for pre-natal care, pregnancy, childbirth, and related medical needs—ensuring every parent has the support they need during this important life moment.8-weeks of paid parental leave for all parents. Additional paid pregnancy leave for CA employees
• Meals & Catering: Frequently catered lunches and team meals, plus company-covered meals when extra time or effort is required
• Snacks & Beverages: Fully stocked kitchen with unlimited snacks and drinks to keep you fueled throughout the day
• Performance & Fitness: $100 monthly fitness stipend to support peak performance and health, both inside and outside of work
• EV Charging: Onsite electric vehicle charging available for employees

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State.

This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply. Failure to obtain or maintain any required clearance or authorization may result in reassignment, leave, or separation from employment, consistent with business needs and applicable law.

Affirmative Action/EEO Statement

Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.