Senior Warhead Design Engineer

Next Matter; Torrance (CA); On-site; USD 140,000 - 190,000; Full time

Benefits offered by this job

Equity & growth

PTO 4 weeks

Holidays 10

Job summary

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

You will own the design, qualification, and testing of energetic components, collaborate with systems, propulsion, and avionics teams, ensure MIL‑STD conformance, perform safety analyses, and document results for DoD programs.

Qualifications

• BS or MS in Mechanical or Aerospace Engineering or related field.
• 5+ years in ordnance or energetics design, analysis and testing.
• Familiarity with DoD and NASA standards (MIL‑STD‑1316, MIL‑STD‑1901A).
• Active or eligible US security clearance; US citizenship required.

Responsibilities

• Own design, development, and qualification of ordnance systems.
• Define requirements across mechanical, electrical, and software boundaries.
• Lead supplier engagement and build-to-print efforts focused on manufacturability, cost, and performance.
• Plan, execute, and analyze ordnance tests (arena testing, function testing, environmental qualification).
• Ensure safe integration with systems across propulsion, avionics, and GNC teams.
• Support FMEA, fault‑tree analysis, and safety case development.
• Maintain documentation and MIL standard compliance.

Skills

Strong communication

Documentation

Hands-on testing

Project leadership

Education

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

Tools

SolidWorks

FEA tools

Job description

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.

Responsibilities

• Own the design, development, and qualification of ordnance systems, including initiators, detonators, transfer charges, explosive bolts, safe‑and‑arm devices.
• Define requirements and interface specifications across mechanical, electrical, and software boundaries.
• Lead supplier engagement, component selection, and build‑to‑print efforts focused on manufacturability, cost, and performance.
• Drive development test planning, execution, and analysis for ordnance systems (arena testing, function testing, 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).
• Hands‑on test experience in high‑consequence environments.
• Strong communication and documentation skills.
• Active or eligible for a U.S. security clearance.
• U.S. citizenship required for 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 at a defense startup or fast‑moving development organization.

Benefits and Perks

All full‑time employees receive meaningful long‑term equity and share in the company’s growth. We offer four weeks of paid time off, ten company‑paid holidays, and comprehensive health, dental, and vision benefits covering 100 % of employee costs with strong dependent coverage. Paid parental leave, a $100 monthly fitness stipend, and onsite EV charging are also provided. Additional perks include catered meals, company‑covered food during high‑demand periods, and a fully stocked kitchen.

Affirmative Action/EEO Statement

Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.