Senior Warhead Design Engineer

Castelion; Rio Rancho (NM); On-site; USD 150,000 - 210,000; Full time

Job summary

Castelion in the United States is seeking a Senior Warhead Design Engineer to lead the design, development, and integration of advanced next‑generation ordnance for long‑range hypersonic strike vehicles.

This hands‑on role requires deep expertise in energetic devices, safe & arm mechanisms, and collaboration with systems, propulsion, avionics, and GNC teams to ensure safe integration.

Qualifications

• B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or related field.
• 5+ years of experience in ordnance or energetics design, analysis, and test
• Familiarity with relevant DoD and NASA standards (e.g., MIL‑STD‑1316, MIL‑STD‑1901A, etc.).
• Hands‑on test experience in high‑consequence environments.
• Strong communication and documentation skills.
• Active or eligible for a U.S. security clearance.

Responsibilities

• Own the design, development, and qualification of ordnance systems, including: Initiators, detonators, transfer charges, explosive bolts, safe & arm devices.
• Define requirements and interface specifications across mechanical, electrical, and software boundaries.
• Lead supplier engagement, component selection, and build‑to‑print efforts with a focus on manufacturability, cost, and performance.
• Drive development test planning, execution, and analysis for ordnance systems (including arena testing, function testing, and environmental qualification).
• Work closely with systems, propulsion, avionics, and GNC teams to ensure ordnance components integrate safely and effectively into the full weapon system.
• Support FMEA, fault‑tree analysis, and safety case development.
• Own documentation and compliance to MIL‑STD‑1316, MIL‑STD‑1910, AFSPCMAN 91‑710, and other relevant standards.

Skills

Ordnance design

DoD/NASA standards

Test experience

Documentation

Security clearance

SolidWorks

FEA tools

Hypersonics

Education

B.S./M.S. in Mechanical or Aerospace Engineering

Tools

SolidWorks

FEA tools

Job description

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

Senior Warhead Design Engineer

Castelion is designing and building next-generation hypersonic weapon systems that restore stability through credible deterrence. We are seeking a hands‑on, mission‑driven Senior Warhead Design Engineer to lead the design, development, and integration of advanced next‑generation systems for our long‑range hypersonic strike vehicles.

This is a high‑impact role for someone with deep expertise in energetic devices and safe & arm mechanisms, who thrives in a fast‑paced, hardware‑rich development environment.

Responsibilities

• Own the design, development, and qualification of ordnance systems, including: Initiators, detonators, transfer charges, explosive bolts, safe & arm devices.
• Define requirements and interface specifications across mechanical, electrical, and software boundaries.
• Lead supplier engagement, component selection, and build‑to‑print efforts with a focus on manufacturability, cost, and performance.
• Drive development test planning, execution, and analysis for ordnance systems (including arena testing, function testing, and environmental qualification).
• Work closely with systems, propulsion, avionics, and GNC teams to ensure ordnance components integrate safely and effectively into the full weapon system.
• Support FMEA, fault‑tree analysis, and safety case development.
• Own documentation and compliance to MIL‑STD‑1316, MIL‑STD‑1910, AFSPCMAN 91‑710, and other relevant standards.

Basic Qualifications

• B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or related field.
• 5+ years of experience in ordnance or energetics design, analysis, and test
• Familiarity with relevant DoD and NASA standards (e.g., MIL‑STD‑1316, MIL‑STD‑1901A, etc.).
• Hands‑on test experience in high‑consequence environments.
• Strong communication and documentation skills.
• Active or eligible for a U.S. security clearance.

Preferred Skills And Experience

• Experience working with DoD customers and navigating military qualification processes.
• Background in hypersonics, missile systems, or space launch vehicles.
• CAD and mechanical analysis experience (e.g., SolidWorks, FEA tools).
• Experience with additive manufacturing tools and capabilities. Prior experience working at a defense startup or fast‑moving development organization.

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

Additional Eligibility Requirements

This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.

Affirmative Action/EEO Statement

Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law. Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact [e-mail]. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law. Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation.

EAR/ITAR Requirements

This position requires access to export‑controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export‑controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.