Senior Mechanical Design Engineer - Flight Hardware

Castelion Corporation; Torrance (CA); On-site; USD 120,000 - 150,000; Full time

Job summary

Castelion is seeking a high-output Senior Mechanical Design Engineer with a full-stack Responsible Engineer mindset to design and deliver critical flight hardware for hypersonic vehicles. You’ll own systems from concept to flight, applying statics, dynamics, and modal analysis to justify designs and prove them in test and flight.

A successful candidate will have 5+ years of ME experience, broad CAD and analysis skills, and a proven track record delivering manufacturable components while

Qualifications

• Broad mechanical knowledge including detailed CAD design of complex parts.
• Tolerance stack-up analysis and thermal analysis.
• Structural analysis and design-to-cost focus for mass-constrained hardware.
• Full-cycle development ownership from concept to production and operations.

Responsibilities

• Lead design, build, and integration of flight vehicle components (e.g., tanks, mechanisms, actuators, control surfaces).
• Guide rapid design iterations with 4-week cadences; participate in design reviews; incorporate test feedback.
• Develop engineering rigor: CAD standards, documentation, and hardware management protocols; assist technicians during assembly.

Skills

CAD design

Tolerance analysis

Thermal analysis

Structural analysis

Design-to-cost

Vendor management

Education

Bachelor's degree in Mechanical Engineering

Job description

Castelion is seeking a high-output Senior Mechanical Design Engineer with a full-stack Responsible Engineer mindset to design and deliver critical flight hardware for hypersonic vehicles. You’ll own systems from concept to flight, applying statics, dynamics, and modal analysis to justify designs and prove them in test and flight.

A successful candidate will have 5+ years of ME experience, broad CAD and analysis skills, and a proven track record delivering manufacturable components while