Senior Mechanical Design Engineer, Attitude Control Systems

Castelion Corporation; Torrance (CA); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Generous benefits package

Job summary

Castelion Corporation in Torrance, CA seeks a Senior Mechanical Design Engineer to design and deliver attitude control system hardware for Castelion's long-range hypersonic strike vehicles. This hands-on role partners with propulsion, GNC, avionics and structures teams to ensure reliable ACS tanks, valves and thrusters.

You will mentor junior engineers, optimize for mass and manufacturability, and contribute to qualification tests and environmental programs.

Qualifications

• 5+ years of experience in mechanical design for aerospace or high-performance fluid/propulsion systems.
• Strong background in pressure vessel design, fluid systems, and high-pressure component integration.
• Experience designing tanks, valves, thrusters, or similar propulsion or ACS hardware.
• Familiarity with sealing methods, leak detection, and cleanliness requirements for high-reliability fluid systems.
• Proficiency in CAD and analysis tools (NX, SolidWorks, ANSYS, or equivalent).
• Experience with structural analysis, thermal analysis, and tolerance stack-up analyses.
• Familiarity with high-temperature materials and operation in extreme environments.
• Experience with hardware build, test, and troubleshooting in a lab or flight hardware environment.

Responsibilities

• Design and develop ACS hardware, including propellant tanks, valves, thrusters, and associated fluid system assemblies.
• Lead the architecture and detailed design of pressure vessels, fluid lines, mounts, and integrated ACS packaging within the vehicle.
• Perform structural, thermal, and fluid analyses to ensure performance and reliability under extreme pressure, temperature, and dynamic environments.
• Work closely with propulsion, GNC, avionics, and structures teams to ensure seamless integration of ACS systems with vehicle architecture.
• Conduct tolerance analysis, sealing strategy development, and leak-tightness assessments for high-pressure systems.
• Support prototyping, assembly, and hardware bring-up, including troubleshooting and root cause analysis of system performance issues.
• Define and execute qualification and environmental test plans, including pressure, vibration, thermal, and shock testing.
• Optimize designs for mass, reliability, manufacturability, and ease of integration.
• Mentor junior engineers and contribute to best practices in mechanical and fluid system design.
• Partner closely with program leadership to make technical trades aligned with mission success.

Skills

Mechanical design

Aerospace systems

CAD tools

NX

SolidWorks

ANSYS

Thermal analysis

Structural analysis

Education

Bachelor's/Master's/PhD in Mechanical Engineering

Tools

NX

SolidWorks

ANSYS

Job description

Castelion Corporation in Torrance, CA seeks a Senior Mechanical Design Engineer to design and deliver attitude control system hardware for Castelion's long-range hypersonic strike vehicles. This hands-on role partners with propulsion, GNC, avionics and structures teams to ensure reliable ACS tanks, valves and thrusters.

You will mentor junior engineers, optimize for mass and manufacturability, and contribute to qualification tests and environmental programs.