Senior Mechanisms Engineer - Aerospace Actuation Systems

Castelion Corporation; Torrance (CA); On-site; USD 150,000 - 190,000; Full time

Benefits offered by this job

Equity for all employees

PTO (paid time off)

Holidays and leave benefits

Health benefits including medical, and

Dental and vision plans

Parental leave

Fitness stipend $100/mo

Onsite EV charging

Catered meals and stocked kitchen

Job summary

Castelion Corporation seeks a Senior Mechanisms Engineer to design high-performance mechanical actuation systems for advanced hypersonic vehicles. You will lead architectures, perform loads/deflections analyses, and collaborate with control electronics, GNC, avionics, and structures teams to ensure robust integration.

Responsibilities include life/reliability assessments, tolerance analyses, prototyping support, and executing environmental test plans to verify performance under extreme flight

Qualifications

• 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.
• 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.
• Experience designing control surface drive systems or similar high-load, high-reliability mechanisms.
• Proficiency in CAD and analysis tools (NX, SolidWorks, ANSYS, or equivalent).
• 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.

Responsibilities

• Design and develop mechanical actuation systems, including elevon drive trains and control surface mechanisms, for high-speed flight vehicles
• Lead the architecture and detailed design of mechanisms, including gear trains, linkages, bearings, and structural components
• Perform analysis of loads, stresses, deflections, and dynamic behavior to ensure performance and reliability under extreme environments
• Work closely with control electronics, GNC, avionics, and structures teams to ensure seamless integration of mechanisms with vehicle systems
• Conduct tolerance analysis, lubrication strategy development, and life/reliability assessments for high-duty-cycle systems
• Support prototyping, assembly, and hardware bring-up, including troubleshooting and root cause analysis of mechanism performance issues
• Define and execute qualification and environmental test plans, including vibration, thermal, and shock testing
• Optimize designs for mass, stiffness, reliability, and manufacturability
• Mentor junior engineers and contribute to best practices in mechanism design and analysis
• Partner closely with program leadership to make technical trades aligned with mission success

Skills

Mechanism design

Aerospace actuators

Gear trains

Loads analysis

Tolerance analysis

EMAs design

Motor-driven actuation

CAD

NX

SolidWorks

ANSYS

Education

Bachelor/Master/PhD in Mechanical Engineering

Tools

NX

SolidWorks

ANSYS

Job description

Castelion Corporation seeks a Senior Mechanisms Engineer to design high-performance mechanical actuation systems for advanced hypersonic vehicles. You will lead architectures, perform loads/deflections analyses, and collaborate with control electronics, GNC, avionics, and structures teams to ensure robust integration.

Responsibilities include life/reliability assessments, tolerance analyses, prototyping support, and executing environmental test plans to verify performance under extreme flight