Senior RF Mechanical Design Engineer - Radomes & Packaging

Castelion; Torrance (CA); On-site; USD 140,000 - 190,000; Full time

Job summary

Castelion seeks a Senior Mechanical Design Engineer to craft RF-transparent radomes and packaging for long-range hypersonic vehicles. You will collaborate across RF, avionics, materials, and thermal teams to ensure structural integrity, thermal survivability, and RF performance during extreme environments.

We value hands-on hardware development, rapid iteration, and mentoring junior engineers to advance best practices in RF structure design and integration with program leadership for mission

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 systems.
• Experience designing radomes, RF-transparent structures, or packaging for RF/antenna systems.
• Familiarity with RF performance considerations such as dielectric properties, insertion loss, and boresight error.
• Strong background in structural and thermal analysis for extreme environments.
• Proficiency in CAD and analysis tools (NX, SolidWorks, ANSYS).
• Experience with tolerance stack-up, alignment, and precision assembly design.
• Familiarity with materials used in RF applications (ceramics, composites, low-loss dielectrics) and high-temperature 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.

Responsibilities

• Design RF-transparent structures, including radomes, windows, and support structures for high-speed flight vehicles.
• Lead RF subsystem packaging architecture, mounting, alignment, and environmental protection of antennas and electronics.
• Perform structural and thermal analyses for extreme environments.
• Collaborate with RF, avionics, materials, and thermal teams to meet RF performance while maintaining integrity.
• Develop interfaces between radomes, TPS, and primary structure with sealing and thermal isolation.
• Conduct tolerance analysis and assess alignment sensitivity on RF performance.
• Support prototyping, assembly, and hardware bring-up, including troubleshooting RF issues.
• Define and execute qualification and environmental test plans (thermal, vibration, RF).
• Optimize designs for mass, thermal performance, RF transparency, and manufacturability.
• Mentor junior engineers and share RF structure best practices.
• Partner with program leadership for technical trade-offs aligned to mission success.

Skills

Mechanical design

RF systems understanding

Structural analysis

Thermal analysis

Problem solving

Education

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

Tools

NX

SolidWorks

ANSYS

Job description

Castelion seeks a Senior Mechanical Design Engineer to craft RF-transparent radomes and packaging for long-range hypersonic vehicles. You will collaborate across RF, avionics, materials, and thermal teams to ensure structural integrity, thermal survivability, and RF performance during extreme environments.

We value hands-on hardware development, rapid iteration, and mentoring junior engineers to advance best practices in RF structure design and integration with program leadership for mission