Senior Mechanical Design Engineer, Hypersonic ACS Propulsion

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

Job summary

Castelion is seeking a Senior Mechanical Design Engineer to design and deliver attitude control system hardware for long-range hypersonic strike vehicles. You will work hands‑on with multidisciplinary teams to create ACS tanks, valves, thrusters, and integrated assemblies in a fast-paced environment.

The role requires 5+ years of aerospace mechanical design experience, strong skills in pressure vessels and fluid systems, and proficiency with CAD/CAE tools.

Qualifications

• 5+ years of aerospace mechanical design experience.
• Strong background in pressure vessels, fluid systems, and high‑pressure integration.
• Experience designing tanks, valves, thrusters, or similar ACS hardware.
• Proficiency with CAD/CAE tools (NX, SolidWorks, ANSYS) and analytic methods.

Responsibilities

• Design and develop ACS hardware, including propellant tanks, valves, thrusters, and fluid system assemblies.
• Lead architecture and detailed design of pressure vessels, fluid lines, mounts, and integrated ACS packaging.
• Perform structural, thermal, and fluid analyses for reliability under extreme conditions.
• Collaborate with propulsion, GNC, avionics, and structures teams for system integration.
• Conduct tolerance analysis, sealing strategy development, and leak-tightness assessments for high-pressure systems.
• Support prototyping, hardware bring-up, and root-cause analysis of performance issues.
• Define and execute qualification and environmental test plans (pressure, vibration, thermal, shock).
• Optimize designs for mass, manufacturability, and ease of integration.
• Mentor junior engineers and contribute to best practices in mechanical/fluid design.

Skills

Aerospace design

Problem solving

Team collaboration

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 and deliver attitude control system hardware for long-range hypersonic strike vehicles. You will work hands‑on with multidisciplinary teams to create ACS tanks, valves, thrusters, and integrated assemblies in a fast-paced environment.

The role requires 5+ years of aerospace mechanical design experience, strong skills in pressure vessels and fluid systems, and proficiency with CAD/CAE tools.