Senior TVC Actuation Engineer for High‑Bandwidth Propulsion

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

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.