Senior Mechanical Design Engineer - Hypersonic ACS Hardware

STEM Boomerang; Rio Rancho (NM); On-site; USD 140,000 - 190,000; Full time

Benefits offered by this job

Meaningful equity

4 weeks paid PTO

Medical plan (100% employee)

Dental & Vision coverage

401k retirement plan

Parental leave

Job summary

Castelion is seeking a Senior Mechanical Design Engineer to design attitude control system hardware for hypersonic strike vehicles. You will develop tanks, valves, thrusters, and integrated assemblies, ensuring reliable propellant storage, flow control, and thrust generation in a fast-paced hardware environment.

You will work with multidisciplinary teams using NX/SolidWorks/ANSYS, applying structural and thermal analyses, and supporting build/test campaigns for flight hardware readiness.

Qualifications

• Bachelor's, Master's, or PhD in Mechanical Engineering or related field
• Experience in aerospace or high-performance fluid/propulsion systems
• Strong background in pressure vessel design and high-pressure integration
• Familiarity with sealing, leak detection, and cleanliness for high-reliability fluid systems
• Proficiency in CAD and analysis tools (NX, SolidWorks, ANSYS)
• Experience with structural and thermal analysis and tolerance stack-up
• Ability to build, test, and troubleshoot hardware in lab/flight environments

Responsibilities

• Design and deliver ACS hardware (tanks, valves, thrusters, assemblies) for long-range hypersonic vehicles
• Collaborate with multidisciplinary teams to enable reliable propellant storage, flow control, and thrust generation
• Analyze and validate hardware through build, test, and integration activities
• Contribute to fast-paced, hardware-driven development with an emphasis on reliability and performance

Skills

Mechanical design

Aerospace propulsion

Fluid systems design

Pressure vessel design

Thermal analysis

Tolerance analysis

Problem solving

Education

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

Tools

NX

SolidWorks

ANSYS

Job description

Castelion is seeking a Senior Mechanical Design Engineer to design attitude control system hardware for hypersonic strike vehicles. You will develop tanks, valves, thrusters, and integrated assemblies, ensuring reliable propellant storage, flow control, and thrust generation in a fast-paced hardware environment.

You will work with multidisciplinary teams using NX/SolidWorks/ANSYS, applying structural and thermal analyses, and supporting build/test campaigns for flight hardware readiness.