R&D Technician

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.

We are seeking an R&D Technician to support hands‑on solid rocket motor (SRM) manufacturing and testing operations at Castelion's development site. Reporting to the Development Site Operations Manager, this role is critical to the safe and effective execution of propellant processing, motor assembly, test setup, and development testing for hypersonic programs including Blackbeard. You will work closely with manufacturing engineers, test engineers, and operations leadership to execute procedures, operate equipment, collect data, and maintain a high standard of safety and quality in a fast‑paced R&D environment involving energetic materials.

• Execute hands‑on propellant manufacturing and SRM assembly tasks according to approved work instructions, including material handling, mixing support, casting operations, curing, and component integration.
• Support test setup, instrumentation installation, hardware preparation, and execution of static fire, environmental, functional, and other development tests under the direction of test engineers and the Site Operations Manager.
• Operate, monitor, and perform basic maintenance on manufacturing and test equipment (mixers, casting systems, ovens, test stands, data acquisition systems, and related tooling).
• Collect, document, and organize process and test data; assist with post‑test hardware recovery, inspection, and data packaging.
• Strictly follow all energetic materials handling, explosive safety, lockout/tagout, and site‑specific safety protocols; actively contribute to a strong safety culture.
• Maintain cleanliness, organization, and readiness of manufacturing and test areas; support 5S and continuous improvement activities.
• Assist with equipment qualification, process trials, procedure validation, and troubleshooting under engineering guidance.
• Prepare and stage materials, tooling, and hardware for builds and tests; support inventory control and material tracking.
• Collaborate daily with engineers, operators, and the Site Operations Manager to meet schedule, quality, and safety objectives.
• Support cross‑training and knowledge sharing as the development site scales capabilities and processes.

• High school diploma or equivalent required. Associate's degree, technical certificate, or equivalent military/technical training in manufacturing, mechanical, electrical, or related field preferred.

• 3+ years of hands‑on experience in manufacturing, assembly, testing, or operations in aerospace, defense, propulsion, chemical processing, or other high‑hazard industrial environments.
• Experience working with energetic materials, hazardous chemicals, or high‑consequence processes is highly desirable.

• Ability to follow detailed work instructions, engineering drawings, and test procedures accurately.
• Hands‑on mechanical aptitude with experience using hand tools, power tools, measuring instruments, and basic shop equipment.
• Comfort operating or supporting process equipment (mixers, ovens, presses, or similar) and test‑related systems.
• Basic familiarity with data collection, instrumentation or computer‑based logging systems.
• Strong attention to detail, documentation discipline, and ability to work safely in a regulated environment.
• Physical ability to lift and handle hardware (typically up to 50 lbs), work in standing positions for extended periods, and operate in industrial/test environments.

• Direct experience supporting solid rocket motor, propellant, munitions, or missile manufacturing or testing.
• Background in aerospace or defense R&D or production environments.
• Experience with static fire testing,…