Senior Warhead Manufacturing & Test Engineer

Castelion; Torrance (CA); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Stock incentives

Medical, vision, and dental insurance

4 weeks paid time off per year

Travel up to 20%

Job summary

Castelion in Torrance, CA seeks a Senior Manufacturing Engineer to lead warhead integration, propellant processing, and test activities across prototype to high-rate production. You will drive manufacturability, quality, and safety while coordinating with suppliers and internal teams.

The role requires 7+ years in aerospace/defense manufacturing, strong IPC/DFM skills, and experience with DoD programs. Eligible to work on-site; travel up to 20% may be required.

Qualifications

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Materials Science, or related field.
• 7+ years in manufacturing engineering for complex aerospace or defense hardware.
• 4+ years supporting warhead, munitions, or energetic-systems integration and test.

Responsibilities

• Lead warhead assembly, integration, and functional test processes for explosive loading, fuze integration, arming/safing mechanisms, and missile-interface mating.
• Develop and execute comprehensive integration & test plans covering component-level, subassembly, and full-warhead verification (including non-destructive inspection, leak testing, electrical continuity, and safe-arm validation).
• Design and qualify production tooling, fixtures, automated work cells, and test stands for precision explosive handling, potting, and environmental stress screening.
• Execute Design for Manufacturability (DFM), PFMEA, control plans, and statistical process control (SPC) to drive first-pass yield >98% and cycle-time reduction.
• Perform root-cause analysis and corrective actions for integration/test failures using 8D, fault-tree, and FRACAS methods; support MRB/FRB and explosive safety reviews.
• Author and maintain manufacturing work instructions, test procedures, travelers, and quality records compliant with AS9100, MIL-STD-810, and customer requirements.
• Scale production lines from prototype to high-rate manufacturing, including capacity modeling, facility layout, and cost-reduction initiatives.
• Collaborate with suppliers on energetic materials and fuze components; implement incoming inspection and supplier quality improvements.
• Drive continuous improvement and technology insertion to support next-generation hypersonic warhead programs.

Skills

Lean manufacturing

DFM

PFMEA

SPC

Root cause analysis

Education

Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Materials Science, or related field

Tools

8D

FRACAS

Job description

Castelion in Torrance, CA seeks a Senior Manufacturing Engineer to lead warhead integration, propellant processing, and test activities across prototype to high-rate production. You will drive manufacturability, quality, and safety while coordinating with suppliers and internal teams.

The role requires 7+ years in aerospace/defense manufacturing, strong IPC/DFM skills, and experience with DoD programs. Eligible to work on-site; travel up to 20% may be required.