Senior Mechanical Design Engineer: Flight Hardware Lead

Castelion Corporation; Torrance, Northern (CA, KY); Hybrid; USD 140,000 - 190,000; Full time

Job summary

Castelion is seeking a high-output Staff Mechanical Design Engineer in Torrance, CA, with 8+ years of experience designing, analyzing, testing, and delivering flight hardware.

You will serve as a domain expert and technical leader, owning mission-critical hardware from concept through flight and mentoring engineers to grow their capabilities. Strong CAD, GD&T, and structural analysis skills are essential.

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 8+ years of professional mechanical engineering experience.
• Demonstrated experience taking complex hardware from concept through design, analysis, manufacturing, integration, test, and operation.
• Deep expertise in at least one mechanical domain, such as mechanisms, structures, avionics packaging, or similar.
• Expert-level CAD and mechanical design skills, including GD&T, tolerance analysis, materials, and manufacturability.
• Strong understanding of structural mechanics, statics, vibration, and FEA.
• Experience designing high-performance hardware with constraints on mass, cost, schedule, reliability, and manufacturability.
• Strong hands-on problem-solving skills and experience working directly with hardware.

Responsibilities

• Own Flight Hardware: Lead the design, analysis, build, integration, and test of critical flight hardware from concept through flight.
• Technical Excellence: Serve as a technical authority in a mechanical domain such as mechanisms, structures, or avionics packaging. Establish and maintain high standards for design, analysis, manufacturability, and flight readiness.
• Structural Analysis: Perform and/or lead structural analysis using first-principles engineering, FEA, statics, vibration, and modal analysis.
• Rapid Development: Drive high-cadence design iterations, incorporating test results and lessons learned into rapid hardware improvements.
• Hands-On Engineering: Work directly with technicians, manufacturing, suppliers, and test teams to troubleshoot hardware and drive problems to closure.
• Engineering Leadership: Mentor engineers through design reviews, technical problem-solving, and hands‑on coaching. Raise the technical capability and engineering standards of the broader team.
• Engineering Rigor: Improve CAD, analysis, documentation, hardware development, and design practices while maintaining speed and technical discipline.

Skills

CAD & FEM

Mechanisms

Structures

Avionics packaging

GD&T & tolerance analysis

Problem solving

Education

Bachelor's degree in Mechanical Engineering

8+ years of professional mechanical engineering experience

Job description

Castelion is seeking a high-output Staff Mechanical Design Engineer in Torrance, CA, with 8+ years of experience designing, analyzing, testing, and delivering flight hardware.

You will serve as a domain expert and technical leader, owning mission-critical hardware from concept through flight and mentoring engineers to grow their capabilities. Strong CAD, GD&T, and structural analysis skills are essential.