Senior Mechanical Engineer, Attitude Control Systems (ACS)

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

Job summary

Castelion is seeking a Senior Mechanical Design Engineer (ACS Systems) to design and deliver attitude control system hardware for long-range hypersonic strike vehicles. You will lead tank, valve, thruster, and integrated assembly design, performing structural, thermal, and fluid analyses for reliability in extreme environments.

You will collaborate with propulsion, GNC, avionics, and structures teams to ensure seamless integration and will mentor junior engineers in best practices for mechanical

Qualifications

• Bachelor's, Master's, or PhD in Mechanical Engineering or related field.
• 5+ years of experience in mechanical design for aerospace or high-performance fluid/propulsion systems.
• Strong background in pressure vessel design, fluid systems, and high-pressure component integration.
• Proficiency in CAD and analysis tools such as NX, SolidWorks, ANSYS.

Responsibilities

• Design and develop ACS hardware, including propellant tanks, valves, thrusters, and associated fluid system assemblies.
• Lead the architecture and detailed design of pressure vessels, fluid lines, mounts, and integrated ACS packaging within the vehicle.
• Perform structural, thermal, and fluid analyses to ensure performance and reliability under extreme pressure, temperature, and dynamic environments.
• Collaborate with propulsion, GNC, avionics, and structures teams for seamless ACS integration.
• Conduct tolerance analysis, sealing strategy development, and leak-tightness assessments for high-pressure systems.
• Support prototyping, assembly, and hardware bring-up, including troubleshooting and root cause analysis.
• Define and execute qualification and environmental test plans, including pressure, vibration, thermal, and shock testing.
• Optimize designs for mass, reliability, manufacturability, and ease of integration.
• Mentor junior engineers and contribute to best practices in mechanical and fluid system design.
• Partner with program leadership to make technical trades aligned with mission success.

Skills

Mechanical design

Pressure vessels

Fluid systems

CAD

Structural analysis

Thermal analysis

Education

Bachelor/Master/PhD in Mechanical Engineering

Tools

NX

SolidWorks

ANSYS

Job description

Castelion is seeking a Senior Mechanical Design Engineer (ACS Systems) to design and deliver attitude control system hardware for long-range hypersonic strike vehicles. You will lead tank, valve, thruster, and integrated assembly design, performing structural, thermal, and fluid analyses for reliability in extreme environments.

You will collaborate with propulsion, GNC, avionics, and structures teams to ensure seamless integration and will mentor junior engineers in best practices for mechanical