Senior Mechanical Design Engineer: High-Temp TPS

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

Job summary

Castelion Corporation seeks a Senior Mechanical Design Engineer to design flight vehicle structures and integrate the thermal protection system (TPS) for hypersonic strike vehicles. You will lead high-temperature structural assemblies, joints, and interfaces to ensure safe operation under extreme conditions.

You will collaborate with materials, TPS, aerothermal, GNC, and manufacturing teams, performing thermal-structural analyses and guiding hardware bring-up, testing, and qualification to

Qualifications

• Bachelor's, Master's, or PhD in Mechanical Engineering or related field.
• 5+ years of experience in structural design and analysis for aerospace or high-performance systems.
• Strong background in high-temperature structures and materials, particularly in TPS-adjacent or aerothermal environments.
• Experience designing separation systems, joints, and structural interfaces for flight hardware.
• Proficiency in CAD and analysis tools (NX, SolidWorks, ANSYS, or equivalent).
• Experience with structural and thermal analysis, including thermal-structural coupling and tolerance stack-up.

Responsibilities

• Design and develop flight vehicle structures, including separating nose tip systems and other components critical to TPS performance.
• Lead the architecture and detailed design of high-temperature structural assemblies, including joints, interfaces, and load paths across TPS and primary structure.
• Perform structural and thermal analyses to ensure performance and reliability under extreme aerothermal, pressure, and dynamic environments.
• Work closely with materials, TPS, aerothermal, GNC, and manufacturing teams to ensure seamless integration of structures with vehicle systems.
• Develop and analyze separation mechanisms and interfaces, ensuring reliable and repeatable operation under flight conditions.

Skills

High-temperature design

Aerospace structures

Problem solving

Cross-functional collaboration

Education

Bachelor/Master/PhD in Mechanical Engineering

Tools

NX

SolidWorks

ANSYS

Job description

Castelion Corporation seeks a Senior Mechanical Design Engineer to design flight vehicle structures and integrate the thermal protection system (TPS) for hypersonic strike vehicles. You will lead high-temperature structural assemblies, joints, and interfaces to ensure safe operation under extreme conditions.

You will collaborate with materials, TPS, aerothermal, GNC, and manufacturing teams, performing thermal-structural analyses and guiding hardware bring-up, testing, and qualification to