Senior Mechanisms Engineer (TVC Actuation)

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

Benefits offered by this job

Generous benefits package

Job summary

Castelion is seeking a Senior Mechanisms Engineer to design and deliver thrust vector control actuation systems for its long-range hypersonic programs. You will work hands-on with multidisciplinary teams to develop TVC actuators, linkages, mounts, and load paths for high-performance propulsion in extreme environments.

The role requires leading design efforts, performing dynamic and reliability analyses, and coordinating with propulsion, control electronics, GNC, and structures groups.

Qualifications

• Bachelor's, Master's, or PhD in Mechanical Engineering or related field.
• 5+ years of experience in mechanism and actuator design for aerospace or high-performance dynamic systems.
• Strong background in electromechanical actuators (EMAs), including motor-driven systems and torque transmission.
• Experience with TVC or similar high-load, high-bandwidth actuation systems.
• Familiarity with motor selection, encoders/resolvers, and actuator feedback integration.
• Proficiency in CAD and analysis tools (NX, SolidWorks, ANSYS).
• Experience with hardware build, test, and troubleshooting in lab/flight environments.
• Ability to thrive in fast-paced, hardware-rich settings.

Responsibilities

• Design TVC actuation systems, including actuators, linkages, mounts, and load paths.
• Lead architecture and detailed design of EMA systems with gear trains and bearings.
• Analyze loads, stiffness, backlash, bandwidth, and dynamic response for precision thrust vectoring.
• Collaborate with propulsion, electronics, GNC, and structures teams for integration.
• Conduct tolerance analysis, lubrication strategy, and life/reliability assessments.
• Support prototyping, assembly, and hardware bring-up; troubleshoot issues.
• Define qualification and environmental test plans (vibration, thermal, shock).
• Optimize designs for mass, stiffness, thermal robustness, reliability, manufacturability.
• Mentor junior engineers and share best practices.

Skills

TVC actuation design

Electromechanical actuators

CAD/CAE tools

Structural analysis

Thermal engineering

Prototyping and test

Cross-functional collaboration

Problem solving

Education

Bachelor's/Master's/PhD in Mechanical Engineering

Tools

NX

SolidWorks

ANSYS

Job description

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.

Senior Mechanisms Engineer (TVC Actuation)

We are seeking a Senior Mechanisms Engineer to design and deliver thrust vector control (TVC) actuation systems for Castelion's long-range hypersonic strike vehicles. This role is critical to enabling precise, high-bandwidth thrust vectoring under extreme dynamic and thermal environments. You will work hands‑on with multidisciplinary engineering teams to design, analyze, build, and validate TVC actuators and associated mechanisms in a fast‑paced, hardware‑driven environment.

Responsibilities

• Design and develop TVC actuation systems, including actuators, linkages, mounts, and load paths for high-performance propulsion systems
• Lead the architecture and detailed design of electromechanical actuator (EMA) systems, including gear trains, bearings, and structural components
• Perform analysis of loads, stiffness, backlash, bandwidth, and dynamic response to ensure precise and stable thrust vectoring performance
• Work closely with propulsion, control electronics, GNC, and structures teams to ensure seamless integration of TVC systems with vehicle architecture
• Conduct tolerance analysis, lubrication strategy development, and life/reliability assessments for high‑duty-cycle, high‑load systems
• Support prototyping, assembly, and hardware bring‑up, including troubleshooting and root cause analysis of actuator and mechanism performance issues
• Define and execute qualification and environmental test plans, including vibration, thermal, and shock testing
• Optimize designs for mass, stiffness, thermal robustness, reliability, and manufacturability
• Mentor junior engineers and contribute to best practices in actuator and mechanism design
• Partner closely with program leadership to make technical trades aligned with mission success

Basic Qualifications

• Bachelor's, Master's, or PhD in Mechanical Engineering or related field
• 5+ years of experience in mechanism and actuator design for aerospace or high-performance dynamic systems
• Strong background in electromechanical actuators (EMAs), including motor-driven systems, gear reduction, and torque transmission
• Experience designing high-load, high-bandwidth actuation systems such as TVC, control surface actuation, or similar applications
• Familiarity with motor selection (e.g., BLDC), position sensing (encoders/resolvers), and actuator feedback integration
• 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

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

Additional Eligibility Requirements

This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.

Affirmative Action/EEO Statement

Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law.

Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact [e-mail]. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law.

Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation.

EAR/ITAR Requirements

This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.