Senior Mechanical Design Engineer, Hypersonic Structures & TPS

STEM Boomerang; Rio Rancho (NM); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Employee equity

4 weeks paid time off

100% employee health coverage

Dental & Vision 90%

FSA/HSA options

401k retirement plan

Paid parental leave

Meals & catering

Snacks & beverages

Fitness stipend

EV charging onsite

Job summary

Castelion in Rio Rancho, NM, seeks a Senior Mechanical Design Engineer to deliver flight vehicle structures for hypersonic strike vehicles, focusing on structural TPS interfaces and high-temperature components. You will work with multidisciplinary teams to design, analyze, build, and validate hardware in a fast-paced environment.

Candidates have a strong background in high-temperature materials, TPS-adjacent structures, and experience with CAD/analysis tools like NX, SolidWorks and ANSYS;

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 TPS-adjacent or aerothermal environments.
• Experience designing separation systems, joints, and structural interfaces for flight hardware.
• Proficiency in CAD and analysis tools (e.g., NX, SolidWorks, ANSYS, or equivalent).
• Experience with structural and thermal analysis, including thermal-structural coupling and tolerance stack-up.
• Familiarity with materials used in high-temperature environments (ceramics, carbon-carbon, refractory metals, or similar).
• Experience with hardware build, test, and troubleshooting in a lab or flight hardware environment.
• Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high flight cadence environment.

Responsibilities

• Design and deliver critical flight vehicle structures interfacing with the thermal protection system (TPS).
• Focus on structural systems that enable TPS integration and high-temperature performance.
• Collaborate with multidisciplinary teams to design, analyze, build, and validate flight-critical structures.

Skills

Structural design

Aerospace experience

High-temperature structures

Thermal-structural analysis

Tolerance stack-up

Problem solving

Education

Bachelor's/Master's/PhD in Mechanical Engineering or related field

Tools

NX

SolidWorks

ANSYS

Job description

Castelion in Rio Rancho, NM, seeks a Senior Mechanical Design Engineer to deliver flight vehicle structures for hypersonic strike vehicles, focusing on structural TPS interfaces and high-temperature components. You will work with multidisciplinary teams to design, analyze, build, and validate hardware in a fast-paced environment.

Candidates have a strong background in high-temperature materials, TPS-adjacent structures, and experience with CAD/analysis tools like NX, SolidWorks and ANSYS;