Senior TVC Mechanisms Engineer - High-Performance Actuation

Castelion Corporation; Torrance (CA); Hybrid; USD 130,000 - 190,000; Full time

Benefits offered by this job

Generous benefits package

Job summary

Castelion Corporation in Torrance, CA is seeking a Senior Mechanisms Engineer to design and deliver thrust vector control actuators for hypersonic strike vehicles. You will work with multidisciplinary teams to develop TVC actuation systems, optimize mass, stiffness, and reliability, and ensure performance under extreme thermal environments.

This hardware-driven role emphasizes hands-on prototyping, testing, and qualification planning, with mentorship of junior engineers and close collaboration

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), motor-driven systems, gear reduction, and torque transmission.
• Experience with high-load, high-bandwidth actuation such as TVC or similar applications.
• Familiarity with motor selection, encoders/resolvers, and actuator feedback integration.
• Proficient in CAD and analysis tools (NX, SolidWorks, ANSYS).
• Experience with structural analysis, fatigue, and tolerance stack-up; high-temperature materials.
• Hardware build, test, and troubleshooting in a lab/flight environment.

Responsibilities

• Design and develop TVC actuation systems, including actuators, linkages, mounts, and load paths.
• Lead architecture and detailed design of EMA systems, gear trains, bearings, and structures.
• Analyze loads, stiffness, backlash, bandwidth, and dynamic response for precision thrust vectoring.
• Collaborate with propulsion, controls, GNC, and structures teams for system integration.
• Perform tolerance analysis, lubrication strategy, and life/reliability assessments.
• Support prototyping, assembly, and hardware bring-up; troubleshoot actuator performance.
• Define qualification and environmental test plans including vibration, thermal, and shock tests.
• Optimize designs for mass, stiffness, thermal robustness, reliability, and manufacturability.
• Mentor junior engineers and share actuator/mechanism best practices.
• Partner with program leadership on technical trades aligned to mission success.

Skills

Mechanism design

Actuator design

EMAs

High-load actuation

Motor selection

Encoders/Resolvers

CAD

ANSYS

Education

Bachelor's/Master's/PhD in Mechanical Engineering

Tools

NX

SolidWorks

ANSYS

Job description

Castelion Corporation in Torrance, CA is seeking a Senior Mechanisms Engineer to design and deliver thrust vector control actuators for hypersonic strike vehicles. You will work with multidisciplinary teams to develop TVC actuation systems, optimize mass, stiffness, and reliability, and ensure performance under extreme thermal environments.

This hardware-driven role emphasizes hands-on prototyping, testing, and qualification planning, with mentorship of junior engineers and close collaboration