Senior Structures & Composites Engineer (Rocket Motor Cases)
STEM Boomerang
Get more replies from employers
Send a job-specific resume in minutes.
Benefits offered by this job
Job summary
Castelion seeks a Senior Structures & Composites Engineer to design and deliver high-performance rocket motor cases for long-range hypersonic strike vehicles. You will work hands-on with multidisciplinary teams to design, analyze, build, and validate composite and metallic motor case structures in a fast-paced, hardware-driven environment.
The role requires a strong background in aerospace structural design and advanced composite materials, with experience in pressure vessels, COPVs, and
Qualifications
- 5+ years of experience in structural and composite design for aerospace or high-performance pressure vessel applications.
- Strong background in composite materials, including filament winding, laminate theory, and failure criteria (Tsai-Wu, Hashin).
- Experience designing pressure vessels, COPVs, or rocket motor cases for high-pressure applications.
- Proficiency in structural analysis tools (ANSYS, Abaqus, NASTRAN or equivalent).
- Familiarity with manufacturing processes for composites, including winding, curing, and inspection methods (e.g., NDI/NDT).
- Experience with proof/burst testing and structural validation of pressure vessels.
- Experience with hardware build, test, and troubleshooting in a lab or production environment.
- Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high test cadence environment.
Responsibilities
- Design and deliver high-performance rocket motor cases for long-range hypersonic vehicles.
- Analyze and validate composite and metallic motor case structures.
- Collaborate with multidisciplinary teams in a hardware-driven environment.
- Lead testing and troubleshooting of motor cases in lab or production settings.
Skills
Education
Tools
Job description
Rio Rancho, United States | Posted on 08/06/2026
Castelion was founded to restore America’s ability to field advanced weapons at speed and scale. Inspired by the engineering urgency of the WWII and Apollo eras, we combine rapid iteration, vertical integration, and scalable manufacturing to deliver affordable, high-performance strike systems. Our mission: rebuild industrial agility to strengthen national security and outpace evolving threats.
About the Role:
We are seeking a Senior Structures & Composites Engineer to design and deliver high-performance rocket motor cases for Castelion's long-range hypersonic strike vehicles. This role is critical to enabling lightweight, high-strength propulsion structures capable of withstanding extreme pressure and thermal environments. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate composite and metallic motor case structures in a fast-paced, hardware-driven environment.
- Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, or related field
- 5+ years of experience in structural and composite design for aerospace or high-performance pressure vessel applications
- Strong background in composite materials, including filament winding, laminate theory, and failure criteria (e.g., Tsai-Wu, Hashin)
- Experience designing pressure vessels, COPVs, or rocket motor cases for high-pressure applications
- Proficiency in structural analysis tools (e.g., ANSYS, Abaqus, NASTRAN, or equivalent)
- Familiarity with manufacturing processes for composites, including winding, curing, and inspection methods (e.g., NDI/NDT)
- Experience with proof/burst testing and structural validation of pressure vessels
- Experience with hardware build, test, and troubleshooting in a lab or production environment
- Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high test cadence environment
- Employee Equity: Meaningful equity forall full-time employees - share value has increased 150x in three years
- Personal Time Off: Four (4) weeks of paidtime off to unplug, reset, and come back sharp—velocity matters,burnout doesn't
- Medical: We offer plans at 100% employeecovered and 80% of dependent coverage
- Dental & Vision: We cover 90%employees and 80% for dependents to ensure you and your family haveaccess to quality preventive and ongoing care
- FSA/HSA: To support long-term health andfinancial resilience, we offer FSA and HSA options that allowemployees to set aside pre-tax dollars for eligible medical anddependent care expenses
- Retirement: 401k plan offered to supportlong term financial growth along side high-impact, high-velocity work
- Paid Parental Leave: We support growingfamilies with meaningful time to bond and recover. Birthing parentsare eligible for up to 10 weeks of paid leave, while non-birthingparents may take up to 4 weeks of paid leave. This time can be usedfor pre-natal care, pregnancy, childbirth, and related medicalneeds—ensuring every parent has the support they need during thisimportant life moment.8-weeks of paid parental leave for allparents. Additional paid pregnancy leave for CA employees
- Meals & Catering: Frequently cateredlunches and team meals, plus company-covered meals when extra timeor effort is required
- Snacks & Beverages: Fully stockedkitchen with unlimited snacks and drinks to keep you fueledthroughout the day
- Performance & Fitness: $100 monthlyfitness stipend to support peak performance and health, both insideand outside of work
- EV Charging: Onsite electric vehiclecharging available for employees
'/%3e%3cpath%20d='M101.744%2012.4726L102.894%2016.1947L99.0021%2013.2201L101.744%2012.4726ZM105.3%208.40937H100.488L99.0026%203.59473L97.5116%208.41047L92.7%208.40385L96.5965%2011.3834L95.1055%2016.1942L99.0021%2013.2196L101.408%2011.3834L105.3%208.40992V8.40937Z'%20fill='white'/%3e%3cdefs%3e%3clinearGradient%20id='paint0_linear_5593_1381'%20x1='90'%20y1='9.44471'%20x2='99'%20y2='9.44471'%20gradientUnits='userSpaceOnUse'%3e%3cstop%20stop-color='%2300AD70'/%3e%3cstop%20offset='0.998594'%20stop-color='%2300B67A'/%3e%3cstop%20offset='1'%20stop-color='%23DCDCE6'/%3e%3c/linearGradient%3e%3c/defs%3e%3c/svg%3e){kind=small}
