Lead Manufacturing Engineer - Avionics

About Castelion

Castelion is bringing a new approach to defense development and production: one that focuses on short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production ’re designing, building, and testing next‑generation long‑range strike weapons systems to give America and its allies a definitive edge and deter future conflicts.

We’re seeking a Lead Manufacturing Engineer to own the end‑to‑end manufacturing process for avionics hardware from initial prototype builds, establishing production processes and tooling, to scaling up and sustaining rate production. In this pivotal leadership role, you will build and lead a world‑class manufacturing engineering team, pushing for innovation and operational excellence that positions us as the nation’s premier hypersonics producer.

• Lead team & technical direction
  • Manage, mentor, and grow a team of manufacturing and test engineers/specialists; set team goals, track metrics, and drive continuous improvement.
• Manufacturing process & production setup
  • Develop, document, and implement manufacturing processes for avionics assemblies (e.g., PCB/PCBA, electromechanical units, harnesses/cabling, mechanical enclosures, etc.).
  • Define and build manufacturing workflows, work instructions, Bill of Materials (BOM / MBOM), assembly/test procedures, and tooling/fixtures required for repeatable production.
  • Plan and design factory/build‑area layout, select tooling and equipment, manage process validation, and commission production.
• Transition from prototype to production
  • Participate in design reviews and provide feedback with a focus on design for manufacture (DFM), design for test (DFT), testability, manufacturability, supply‑chain considerations, and quality.
  • Work cross‑functionally with design engineering, quality control, supply chain, procurement, and program management to ensure timely delivery, compliance to requirements, and cost & schedule objectives.
• Quality, testing, and reliability assurance
  • Develop and implement test processes (functional testing, environmental testing, acceptance testing as required: e.g., vibration, thermal, EMI/EMC, environmental stress screening) for avionics units, including test benches, fixtures, and automated test systems when needed.
  • Lead root‑cause investigations, corrective action plans, and process improvements when manufacturing or test anomalies occur.
  • Define, track and improve manufacturing metrics: yields, throughput, cost per unit, scrap/rework rates, lead times, etc.
• Continuous Improvement
  • Champion continuous improvement initiatives using Lean/CI methodologies (e.g., 5S, value‑stream mapping, waste reduction, process optimization).
• Documentation & Compliance
  • Ensure all manufacturing, assembly, test and quality processes are properly documented (work instructions, procedures, change orders, non‑conformance procedures, etc.).
  • Support audits, configuration‑management and traceability requirements typical in defense/aerospace industry environments.

• Bachelor’s degree in engineering
• 5+ years of experience in a manufacturing environment with avionics, electronics, PCB/PCBA, and/or complex electromechanical hardware.
• Demonstrated success in scaling a production operation from development/prototype to high‑volume production.
• Experience in leading or mentoring engineers/technicians, and demonstrated team leadership / people management abilities.
• Strong working knowledge of electronics hardware manufacturing: EEE components, PCBs, electromechanical assemblies, wiring/harnesses, test equipment, and relevant manufacturing techniques.
• Excellent communication, interpersonal, and cross‑functional collaboration skills to interface with engineering, quality, supply‑chain, and leadership.
• Demonstrated commitment to safety, quality, and compliance.

• Comfort operating in a fast‑paced, high‑stakes, high‑reliability environment typical of aerospace/defense startups able to make decisions under ambiguity, handle programmatic/contract demands, and adapt as priorities shift.
• Experience with…