Senior Manufacturing Engineer - Warhead Integration & Test

Next Matter; Torrance (CA); On-site; USD 100,000 - 140,000; Full time

Benefits offered by this job

Long-term stock incentives

Comprehensive medical, vision, and dental insurance

Four weeks of paid time off per year

Job summary

A defense development company is looking for a Senior Manufacturing Engineer to lead the warhead integration and testing processes. The ideal candidate will have extensive experience in manufacturing engineering, specifically with energetic materials and defense systems. Responsibilities include leading explosive loading processes, designing production tooling, and executing test plans. Candidates must possess a related Bachelor's degree and at least 7 years of experience in the aerospace or defense sector. This role also offers competitive benefits including stock incentives and comprehensive medical insurance.

Qualifications

• 7+ years in manufacturing engineering for complex aerospace or defense hardware.
• Proven success transitioning warhead or ordnance hardware from prototype through LRIP to full-rate production.
• 4+ years supporting warhead, munitions, or energetic-systems integration and test.

Responsibilities

• Lead warhead assembly, integration, and functional test processes for explosive loading.
• Develop and execute comprehensive integration & test plans.
• Design and qualify production tooling and fixtures for precision handling.
• Perform root-cause analysis for integration/test failures.

Skills

Manufacturing Engineering

Process Development

Propellant Formulation

Root-Cause Analysis

Team Collaboration

Creative Problem Solving

Education

Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Materials Science, or related field

Job description

About Castelion

Castelion is bringing a new approach to defense development and production: one that focuses on short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production at scale. We’re designing, building, and testing next generation long‑range strike weapons systems to give America and its Allies a definitive edge and deter future conflicts.

Senior Manufacturing Engineer – Warhead Integration & Test

Castelion is seeking an experienced Materials & Process Engineer to serve as the company’s technical authority for solid rocket motor propellant. This individual will play a critical role in developing, qualifying, and scaling propellant formulations and manufacturing processes to meet performance, production rate, and safety requirements.

The successful candidate will bring deep expertise in energetic materials, along with hands‑on experience in propellant formulation, production‑scale process development, and characterization.

Responsibilities

• Lead warhead assembly, integration, and functional test processes for explosive loading, fuze integration, arming/safing mechanisms, and missile‑interface mating.
• Develop and execute comprehensive integration & test plans covering component‑level, subassembly, and full‑warhead verification (including non‑destructive inspection, leak testing, electrical continuity, and safe‑arm validation).
• Design and qualify production tooling, fixtures, automated work cells, and test stands for precision explosive handling, potting, and environmental stress screening.
• Execute Design for Manufacturability (DFM), PFMEA, control plans, and statistical process control (SPC) to drive first‑pass yield >98% and cycle‑time reduction.
• Perform root‑cause analysis and corrective actions for integration/test failures using 8D, fault‑tree, and FRACAS methods; support MRB/FRB and explosive safety reviews.
• Author and maintain manufacturing work instructions, test procedures, travelers, and quality records compliant with AS9100, MIL‑STD‑810, and customer requirements.
• Scale production lines from prototype to high‑rate manufacturing, including capacity modeling, facility layout, and cost‑reduction initiatives.
• Collaborate with suppliers on energetic materials and fuze components; implement incoming inspection and supplier quality improvements.
• Drive continuous improvement and technology insertion to support next‑generation hypersonic warhead programs.

Basic Qualifications

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Materials Science, or related field.
• 7+ years in manufacturing engineering for complex aerospace or defense hardware.
• 4+ years specifically supporting warhead, munitions, or energetic‑systems integration and test (or equivalent high‑reliability explosive assembly).
• Proven success transitioning warhead or ordnance hardware from prototype through LRIP to full‑rate production.

Preferred Skills and Experience

• Direct work on DoD warhead programs, hypersonic strike systems, or conventional munitions.
• Experience in fast‑paced defense environments.
• Background with insensitive munitions (IM), shaped‑charge, or multi‑mode warhead designs.
• Familiarity with ITAR‑controlled programs, ATF regulations, and classified manufacturing protocols.

Additional Requirements

• Must be willing to work extended hours and/or weekends as needed.
• Must be able to travel up to 20%.
• All employees are granted long‑term stock incentives as part of their employment at Castelion. All employees receive access to comprehensive medical, vision, and dental insurance, and the company offers four weeks of paid time off per year.

Leadership Qualities

• Bias to Action and Creative Problem Solving. Desire and experience questioning assumptions in ways that lead to breakthrough ideas that are ultimately implemented. Successfully bring in applicable processes/concepts/materials from other industries to achieve efficiency gains. Ability to personally resolve minor issues in development without requiring significant support.
• High Commitment, High Initiative. A successful candidate will have a genuine passion for Castelion’s mission and consistently look for ways to contribute to the company’s technical goals and prevent hardware blockers. Ability to work in a fast paced, autonomously driven, and demanding atmosphere. Strong sense of accountability and integrity.
• Clear Communicator. Proactively communicates blockers. Trusted in previous roles to be voice of company with regulators, suppliers, gate keepers and customers. Capable of tactfully managing relationships with stakeholders to achieve company‑desired outcomes without compromising relationships. Emails, IMs and verbal interactions are logical, drive clarity, and detailed enough to eliminate ambiguity.

ITAR Requirements

• 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.

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.