Senior Test Engineer - Propulsion & Hypersonics

Castelion Corporation; Rio Rancho, Northern (NM, KY); Hybrid; USD 120,000 - 180,000; Full time

Benefits offered by this job

Generous benefits package

Job summary

Castelion Corporation seeks a Senior Test Engineer to lead testing activities for solid rocket motors and hypersonic systems. This hands-on role focuses on static fire testing, environmental qualification, and flight test support in a fast-paced defense environment.

You will partner with Propulsion, Manufacturing, and Design teams to drive test readiness for prototype through production hardware at sites including Rio Rancho, NM, and Midland, TX.

Qualifications

• Bachelor’s or Master’s degree in Mechanical, Aerospace, or Systems Engineering.
• 6–10+ years of test engineering experience in aerospace/defense, with 3+ years propulsion/testing.
• Proven track record managing complex test programs from component to system level.

Responsibilities

• Lead the development of comprehensive test plans, procedures, and requirements for SRM static fires, environmental testing, functional checkout, and vehicle-level integration testing.
• Design, commission, and operate test fixtures, instrumentation setups, and data acquisition systems for thrust, pressure, temperature, vibration, and other critical parameters.
• Execute and oversee static fire tests, environmental stress screening, and other qualification tests, ensuring safe operations with energetic materials and high-consequence hardware.
• Perform real-time test monitoring, data reduction, analysis, and reporting; identify anomalies and lead root-cause investigations with cross-functional teams.
• Support flight test campaigns, including pre-flight checkout, range coordination, telemetry monitoring, and post-flight data analysis.
• Drive continuous improvement in test processes, safety protocols, and efficiency while integrating automation and digital tools for data capture and analysis.
• Collaborate with Manufacturing and Propulsion on testability, design-for-test feedback, and hardware maturation from prototype to rate production.
• Author and maintain test documentation, safety plans, and compliance records in accordance with DoD, range safety, and energetic materials standards.
• Mentor junior test engineers and contribute to building robust test capabilities at Castelion facilities and partner ranges.
• Manage test schedules, resources, and interfaces with internal teams, suppliers, and external test ranges.

Skills

Test instrumentation

LabVIEW

MATLAB

Data acquisition

Thermocouples & sensors

Test stand design

Environmental testing

Telemetry

Safety protocols

Education

Bachelor’s or Master’s in Mechanical Engineering

Aerospace Engineering

Systems Engineering

Tools

LabVIEW hardware

DAQ systems

Environmental chambers

Shakers

Job description

Castelion Corporation seeks a Senior Test Engineer to lead testing activities for solid rocket motors and hypersonic systems. This hands-on role focuses on static fire testing, environmental qualification, and flight test support in a fast-paced defense environment.

You will partner with Propulsion, Manufacturing, and Design teams to drive test readiness for prototype through production hardware at sites including Rio Rancho, NM, and Midland, TX.