Materials Engineer – Temperature Composites No No department On-Site

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.

Castelion is seeking a highly motivated recent graduate or early‑career engineer to support R&D development and scale‑up of our ceramic matrix composite (CMC) fabrication processes. This role will support composite layup and densification operations which are part of the production workflow for high‑performance thermal protection system (TPS) materials.

The position is ideal for a recent graduate with an interest in ceramic matrix composite material process development and scaling large‑scale production systems of high‑performance aerospace parts. It will involve hands‑on composite fabrication work with analytical and process engineering responsibilities. The engineer will support prepreg layup and part shaping operations compression, curing, resin infiltration, and high‑temperature pyrolysis processes. In addition, the engineer will characterize fabricated materials, develop drive data collection and analysis of the different sub‑processes, and contribute to improving process repeatability and manufacturing readiness across the pilot line.

• Support composite layup, shaping, and densification operations to deliver a completed TPS demonstrator part set by the end of the year.
• Own all process QA data collection activities and database management.
• Conduct characterization activities of all finished C/SiC goods to assess performance and inform development strategies.
• Assist with prepreg layup, compression molding, filament winding, curing, resin infiltration, and pyrolysis operations for CMC components.
• Perform characterization and inspection of composite materials using standard laboratory techniques.
• Collect, organize, and analyze process and material performance data to support process optimization.
• Develop and maintain process documentation, work instructions, and standardized operating procedures.
• Support installation, maintenance, and scale‑up of pilot‑line manufacturing hardware.

• Bachelor's or Master's degree in Materials Science, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, or related field.
• Familiarity with materials characterization techniques (mechanical testing, metallographic mounting and polishing, SEM).
• Must be willing to work weekends when necessary.
• Ability to work independently in a hands‑on engineering environment.

• Experience in a research and development environment.
• Previous involvement in a high‑speed production environment, handling flight hardware.
• Prior involvement in a high‑output environment, involving hands‑on experience in constructing solid rocket motors or similar energetics.
• Ability to acclimate to frequently changing assignments and a fast‑paced working environment.
• Excellent communication skills, both written and oral, along with effective teamwork abilities.
• Superb focus and attention to detail, with remarkable work efficiency and accuracy.
• Use of hand tools, power tools and fabrication tools.
• Expertise in manufacturing and repairing intricate testing systems.
• Familiarity with Atlassian tools such as SVN, Confluence, and JIRA.
• Skills in project management.

• Employee Equity:
  Meaningful equity for all full‑time employees – share value has increased 150x in three years.
• Personal Time Off:
  Four (4) weeks of paid time off to unplug, reset, and come back sharp.
• Company Paid Holidays:
  Ten (10) company paid holidays.
• Medical:
  We offer plans at 100 % employee covered and 80 % of dependent coverage.
• Dental & Vision:
  We cover 90 % employees and 80 % for dependents to ensure you and your family have access to quality preventive and ongoing care.
• FSA/HSA:
  To support…