Manufacturing Engineer - Case Lining & Paint

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 e designing, building, and testing next generation long range strike weapons systems to give America and its Allies a definitive edge and deter future conflicts.

Manufacturing Engineer - Case Lining & Paint

Castelion is seeking a Manufacturing Engineer to own the complete case lining, insulation, and protective coating value stream for our solid rocket motor programs. This hands-on individual contributor role will develop, qualify, and scale repeatable, rate-capable processes for internal insulation application, liner dispensing, case bonding verification, and external thermal-protection and paint systems.

Own all case preparation, insulation layup/hand-off, robotic and manual liner application, external insulation closeout, and paint systems. Develop and qualify new liner formulations, spray/robotic dispensing programs, and cure cycles that meet bond-line strength, peel, and aging requirements across environmental extremes.

Lead investigation and permanent elimination of liner/insulation. Implement real-time process monitoring (laser profiling, viscosity control, environmental logging) to achieve first-pass bond-line acceptance and zero paint rework.

Drive transition from manual layup and brush/roller application to fully robotic lining cells, automated spray booths, and high-throughput paint lines. Specify, procure, and commission equipment including plural-component robotic dispensers, plasma/laser surface-treatment systems, and IR/UV cure ovens.

Design or specify rotating case fixtures, expandable mandrels, robotic end-effectors, liner transfer pots, and clean-room layouts that support simultaneous processing of multiple large-diameter cases while maintaining ESD, FOD, and explosive safety standards.

Author hazard analyses, SOPs, and safety submissions liners, solvent-based paints, and spray. Maintain strict VOC, HAP, and personnel exposure controls. Lead change-control for any material or process chemistry changes.

Partner with Design Engineering during case and grain-design phases to ensure producible bond surfaces, accessible geometries, and compatible material systems. Generate PFMEAs, control plans, and qualification plans for new insulation/liner stacks. Execute first-article lining and paint on development and qualification motors.

Serve as the primary point of contact for all bond-line and coating non-conformances. Perform or oversee pull tests, lap-shear testing, surface energy measurement, and cross-sectional analysis. Present technical data and corrective actions directly to Quality, EHS, and government/customer representatives.

• Bachelors degree in Mechanical, Aerospace, Chemical, Materials, or Manufacturing Engineering.
• Minimum 5 years of direct hands-on experience with composites and bonding, ideally with case internal insulation, liner application, and aerospace-grade coating systems.

• Track record of developing and qualifying new liner and paint systems for DoD tactical, missile-defense, or space-launch motors.
• Hands-on experience scaling case lining and paint processes
• Familiarity with automated vision inspection, laser surface profiling, and statistical process control of coating thickness and bond integrity.
• Ability to obtain and maintain a U.S. DoD security clearance.

• Bias to Action and Creative Problem Solving
  . Desire and experience questioning assumptions in ways that lead to break through ideas that are ultimately implemented. Successfully bring in applicable processes/concepts/materials from other industries to achieve efficiency gains. Ability to personally resolve minor issues in development without requiring…