Senior Warhead Design Engineer, Hypersonic Systems

Castelion; Torrance (CA); On-site; USD 140,000 - 210,000; Full time

Job summary

Castelion is seeking a hands-on Senior Warhead Design Engineer to lead the design, development, and integration of advanced ordnance systems for our hypersonic strike programs.

The role requires 5+ years in ordnance or energetics, experience with MIL‑STD standards, CAD/FEA tools, and the ability to work across mechanical, electrical, and software teams in a fast-moving, hardware‑driven environment. Active US security clearance or eligibility is required.

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

Energetics

Test experience

DoD standards

Security clearance

Communication

Documentation

CAD

FEA tools

Additive manufacturing

Education

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

Tools

SolidWorks

FEA tools

CAD

Additive manufacturing

Job description

Castelion is seeking a hands-on Senior Warhead Design Engineer to lead the design, development, and integration of advanced ordnance systems for our hypersonic strike programs.

The role requires 5+ years in ordnance or energetics, experience with MIL‑STD standards, CAD/FEA tools, and the ability to work across mechanical, electrical, and software teams in a fast-moving, hardware‑driven environment. Active US security clearance or eligibility is required.