Senior Manufacturing Engineer, Radar

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.

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.

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State.

This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements.

You will be notified if and when such requirements apply. Failure to obtain or maintain any required clearance or authorization may result in reassignment, leave, or separation from employment, consistent with business needs and applicable law.

• 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…