Senior Mechanisms Engineer — Precision Actuation for Flight

Castelion; Torrance (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

Castelion is seeking a Senior Mechanisms Engineer to design and deliver high-performance actuation systems for hypersonic flight vehicles. You will work with multidisciplinary teams to create elevon drive trains and precise control surface mechanisms in a fast-paced, hardware-driven environment.

The role requires 5+ years in aerospace mechanism design, proficiency in CAD/analysis tools, and hands-on experience with EMAs, motor-driven actuation, and rigorous testing under extreme conditions.

Qualifications

• Bachelor's, Master's, or PhD in Mechanical Engineering or related field.
• 5+ years of mechanism design, analysis, and validation for aerospace or high-performance mechanical systems.
• Experience with electromechanical actuators (EMAs) for aerospace or demanding applications.
• Familiarity with motor-driven actuation systems, gear reduction, torque transmission, and feedback.
• Proficient in CAD and analysis tools for high-load, high-reliability mechanisms.

Responsibilities

• Design and develop mechanical actuation systems, elevon drive trains, control surface mechanisms.
• Lead architecture and detailed design of gear trains, linkages, bearings, and structural components.
• Analyze loads, stresses, deflections, and dynamic behavior for extreme environments.
• Collaborate with control electronics, GNC, avionics, and structures teams for integration.
• Define qualification and environmental test plans including vibration, thermal, and shock.
• Support prototyping, assembly, and hardware bring-up, troubleshooting root causes.
• Mentor junior engineers and contribute to mechanism best practices.
• Partner with program leadership on technical trades aligned with mission.

Skills

Mechanism design

Analysis & validation

Aerospace experience

EMAs design

CAD tools

Education

Bachelor's in Mechanical Engineering

Master's or PhD preferred

Tools

NX

SolidWorks

ANSYS

Job description

Castelion is seeking a Senior Mechanisms Engineer to design and deliver high-performance actuation systems for hypersonic flight vehicles. You will work with multidisciplinary teams to create elevon drive trains and precise control surface mechanisms in a fast-paced, hardware-driven environment.

The role requires 5+ years in aerospace mechanism design, proficiency in CAD/analysis tools, and hands-on experience with EMAs, motor-driven actuation, and rigorous testing under extreme conditions.