Senior Manufacturing Engineer, Radar

About the job Senior Manufacturing Engineer, Radar

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 and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.

This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.

Senior Manufacturing Engineer – Avionics Electro-Mechanical Assembly

We are seeking a Senior Manufacturing Engineer with deep expertise in the high-reliability assembly and integration of avionics and electromechanical systems for hypersonic missile vehicles. This role focuses on developing, optimizing, and scaling manufacturing processes for complex avionics hardware—including printed circuit board assemblies (PCBA), wire harnesses, electronic enclosures, sensors, actuators, connectors, and electromechanical subassemblies—to achieve repeatable, high-yield production.

You will serve as the technical authority on avionics electromechanical manufacturing, partnering with design, integration & test, quality, supply chain, and automation teams to transition advanced avionics from prototype to high-rate production while meeting stringent DoD, AS9100, IPC, and mission‑critical reliability standards.

• Lead manufacturing process development for avionics electromechanical assembly, including PCBA integration, conformal coating, potting, wire harness routing, connector termination, and enclosure sealing.
• Design and qualify production tooling, fixtures, automated work cells, and test equipment for precision electromechanical build and functional verification.
• Execute Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, and control plans to drive first‑pass yield >95% and aggressive cycle‑time reduction.
• Establish statistical process control (SPC), in‑process inspection, and metrology strategies for critical avionics parameters (torque, continuity, insulation resistance, leak testing).
• Scale production from low‑rate initial production (LRIP) to full‑rate manufacturing, including line balancing, capacity modeling, and cost‑reduction initiatives.
• Perform root‑cause analysis and corrective actions for assembly defects using 8D, fishbone, and fault‑tree methods; support MRB/FRB dispositions.
• Author and maintain detailed work instructions, travelers, and quality records compliant with customer requirements.
• Collaborate with suppliers on incoming material qualification for PCBs, connectors, and electromechanical components.
• Drive continuous improvement projects targeting cost, quality, and throughput for next‑generation hypersonic avionics programs.

• Bachelor's in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, or related field.
• 7+ years in manufacturing engineering for complex aerospace or defense electronics hardware.
• 4+ years specifically supporting avionics or electromechanical assembly and integration (high‑reliability electronics preferred).
• Proven success transitioning avionics hardware from prototype through LRIP to full‑rate production.

• Proficient with 3D CAD (Solid Works or NX), GD&T (ASME Y14.5), and tolerance stack‑up analysis.
• Strong experience in precision electromechanical assembly processes, including soldering, crimping, potting, adhesive bonding, and cleanroom/ESD protocols.
• Familiarity with ERP/MES systems and manufacturing execution for full aerospace traceability.
• Working knowledge of environmental stress screening (ESS), vibration, thermal cycling, and functional test integration for avionics.
• Direct work on missile, hypersonic, or high‑reliability avionics systems for DoD programs.
• Experience in fast‑paced defense or space environments (e.g., Anduril or Space
  
  X)
• Background with harsh‑environment electronics (high‑G, thermal extremes, radiation).
• Track record of implementing automation for electromechanical assembly and achieving significant cost or cycle‑time reductions.
• Famili…