Warhead Integration & Test Manufacturing Lead

Castelion; Rio Rancho (NM); On-site; USD 100,000 - 130,000; Full time

Job summary

Castelion in the United States is seeking a Senior Manufacturing Engineer focused on warhead integration and test to drive production readiness from prototype to full-rate manufacturing. You will own assembly, test plans, tooling design, and process controls in a fast-paced defense environment.

You will lead DFMEA, SPC, and quality records, collaborate with suppliers of energetic materials, and ensure compliance with AS9100, MIL-STD-810, ITAR, and customer requirements while delivering high

Qualifications

• 7+ years in manufacturing engineering for complex aerospace or defense hardware.
• 4+ years supporting warhead, munitions, or energetic-systems integration and test (or equivalent high-reliability explosive assembly).
• Proven success transitioning warhead hardware from prototype through LRIP to full-rate production.

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.

Skills

Aerospace/defense manufacturing

Warhead integration experience

Process development

DFMEA/SPC/Quality systems

Education

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

Tools

AS9100

MIL-STD-810

ITAR compliance

Job description

Castelion in the United States is seeking a Senior Manufacturing Engineer focused on warhead integration and test to drive production readiness from prototype to full-rate manufacturing. You will own assembly, test plans, tooling design, and process controls in a fast-paced defense environment.

You will lead DFMEA, SPC, and quality records, collaborate with suppliers of energetic materials, and ensure compliance with AS9100, MIL-STD-810, ITAR, and customer requirements while delivering high