Senior Sheet Metal Forming & Welding Engineer

Castelion Corporation; Torrance, Northern (CA, KY); Hybrid; USD 120,000 - 180,000; Full time

Job summary

Castelion Corporation in Torrance, CA seeks a Senior Manufacturing Engineer to own sheet metal forming and welding for solid rocket motor hardware, developing, qualifying, and scaling flight‑worthy fabrication.

You will define forming methods, weld procedures, and inspection plans, partnering with Design, Quality, Tooling, Automation, and Operations to deliver repeatable production from development through high‑rate production.

Qualifications

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
• 6–10+ years in aerospace/defense/high-reliability metallic fabrication.
• 3+ years hands-on ownership of sheet metal forming and welding on flight or mission-critical hardware.

Responsibilities

• Own manufacturing processes for sheet metal forming and welding, including cutting, bending, rolling, hydroforming or equivalent forming methods, fit-up, welding, post-weld processing, and final inspection.
• Develop and qualify weld procedures, forming processes, fixtures, and work instructions meeting dimensional, structural, and quality requirements.
• Execute DFM/DFA, PFMEA, control plans, and SPC to improve first-pass yield, cycle time, and cost.
• Define inspection and NDE strategies for formed and welded hardware (dimensional inspection, visual weld inspection, and approved NDE methods).
• Partner with Tooling, Automation & Controls on forming dies, weld fixtures, positioners, and semi-automated or robotic welding cells.
• Support new product introduction and design changes with producibility input on material selection, bend radii, weld joint design, tolerances, and assembly sequence.
• Lead root-cause analysis and corrective actions for forming defects, weld defects, distortion, fit-up issues, and dimensional escapes.
• Author and maintain travelers, WPS/PQR support documentation as applicable, and quality records compliant with AS9100 and customer requirements.
• Collaborate with suppliers on sheet stock, formed details, and welded subassemblies; drive incoming quality and process capability.

Skills

Sheet metal forming

Welding

DFM/DFA

PFMEA

SPC

GD&T

Metrology

Documentation

Education

Bachelor's degree in Manufacturing/Mechanical/Welding Engineering, Materials Science or related field

Tools

SolidWorks

NX

Job description

Castelion Corporation in Torrance, CA seeks a Senior Manufacturing Engineer to own sheet metal forming and welding for solid rocket motor hardware, developing, qualifying, and scaling flight‑worthy fabrication.

You will define forming methods, weld procedures, and inspection plans, partnering with Design, Quality, Tooling, Automation, and Operations to deliver repeatable production from development through high‑rate production.