Senior Mechanisms Engineer

STEM Boomerang; Rio Rancho (NM); On-site; USD 110,000 - 165,000; Full time

Benefits offered by this job

Meaningful equity for full-time

4 weeks paid time off

Medical: 100% employee coverage

Dental & Vision coverage

Retirement: 401k plan

Parental leave

Job summary

Castelion is seeking a Senior Mechanisms Engineer to design and deliver high-performance mechanical actuation systems for long-range hypersonic strike vehicles. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate mechanisms such as elevon drive trains in a fast-paced hardware-driven environment.

The role requires advanced degrees in mechanical engineering and 5+ years in mechanism design, with experience in aerospace-grade actuators, CAD tools,

Qualifications

• 5+ years of experience in mechanism design, analysis, and validation for aerospace or high-performance mechanical systems.
• Familiarity with high-temperature materials and operation in extreme environments.
• Experience with hardware build, test, and troubleshooting in lab/flight hardware.

Responsibilities

• Design, analyze, build, and validate high-performance mechanical actuation systems for hypersonic vehicles.
• Collaborate with multidisciplinary teams to ensure precise control surface motion and deployment under extreme flight conditions.

Skills

Mechanism design

Gear trains

Actuation systems

Electromechanical actuators

Motor-driven actuation

CAD proficiency

Education

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

Tools

NX

SolidWorks

ANSYS

Job description

Rio Rancho, United States | Posted on 08/06/2026

Castelion was founded to restore America’s ability to field advanced weapons at speed and scale. Inspired by the engineering urgency of the WWII and Apollo eras, we combine rapid iteration, vertical integration, and scalable manufacturing to deliver affordable, high-performance strike systems. Our mission: rebuild industrial agility to strengthen national security and outpace evolving threats.

About the Role:

We are seeking a Senior Mechanisms Engineer to design and deliver high-performance mechanical actuation systems for Castelion's long-range hypersonic strike vehicles. This role is critical to enabling precise and reliable control surface motion and deployment mechanisms under extreme flight conditions. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate mechanisms such as elevon drive trains and related actuation systems in a fast-paced, hardware-driven environment.

Requirements

• Bachelor's, Master's, or PhD in Mechanical Engineering or related field
  
• 5+ years of experience in mechanism design, analysis, and validation for aerospace or high-performance mechanical systems
  
• Strong background in gear trains, actuation systems, and precision mechanical design
  
• Experience designing electromechanical actuators (EMAs) for aerospace or similarly demanding applications
  
• Familiarity with motor-driven actuation systems, including motor selection, gear reduction, torque transmission, and position feedback mechanisms
  
• Proficiency in CAD and analysis tools (e.g., NX, SolidWorks, ANSYS, or equivalent)
  
• Experience with structural analysis, fatigue/life assessment, and tolerance stack-up analysis
  
• Familiarity with high-temperature materials, lubrication strategies, and operation in extreme environments
  
• 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
  
• Employee Equity: Meaningful equity forall full-time employees - share value has increased 150x in three years
  
• Personal Time Off: Four (4) weeks of paidtime off to unplug, reset, and come back sharp—velocity matters,burnout doesn't
  
• Medical: We offer plans at 100% employeecovered and 80% of dependent coverage
  
• Dental & Vision: We cover 90%employees and 80% for dependents to ensure you and your family haveaccess to quality preventive and ongoing care
  
• FSA/HSA: To support long-term health andfinancial resilience, we offer FSA and HSA options that allowemployees to set aside pre-tax dollars for eligible medical anddependent care expenses
  
• Retirement: 401k plan offered to supportlong term financial growth along side high-impact, high-velocity work
  
• Paid Parental Leave: We support growingfamilies with meaningful time to bond and recover. Birthing parentsare eligible for up to 10 weeks of paid leave, while non-birthingparents may take up to 4 weeks of paid leave. This time can be usedfor pre-natal care, pregnancy, childbirth, and related medicalneeds—ensuring every parent has the support they need during thisimportant life moment.8-weeks of paid parental leave for allparents. Additional paid pregnancy leave for CA employees
  
• Meals & Catering: Frequently cateredlunches and team meals, plus company-covered meals when extra timeor effort is required
  
• Snacks & Beverages: Fully stockedkitchen with unlimited snacks and drinks to keep you fueledthroughout the day
  
• Performance & Fitness: $100 monthlyfitness stipend to support peak performance and health, both insideand outside of work
  
• EV Charging: Onsite electric vehiclecharging available for employees