Manager - Tooling, Automation & Controls

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 Manager of Tooling, Automation & Controls to lead the design, development, deployment, and sustainment of advanced manufacturing tooling and automated systems for hypersonic missile production. This role owns the full lifecycle of custom tooling, fixtures, automated work cells, robotic systems, and industrial controls architectures supporting solid rocket motors, seekers, warheads, avionics, and vehicle integration. You will build and lead a high‑performing team of tooling engineers, automation specialists, and controls engineers to deliver scalable, high‑reliability manufacturing solutions that enable rapid iteration and high‑rate production while meeting stringent DoD, AS9100, ITAR, and explosive‑safety requirements.

• Lead a multidisciplinary team responsible for all manufacturing tooling, automation, and controls across Castelion’s production programs.
• Oversee the design and qualification of precision tooling and fixtures for composite filament winding, propellant casting, avionics integration, and final vehicle build.
• Architect and deploy automated manufacturing cells, robotic systems, and motion‑control solutions for high‑precision, hazardous, and high‑volume processes.
• Direct controls system development (PLC, HMI, SCADA, motion control, safety PLC) with full compliance to functional safety and Class I Div 1 / hazardous location standards.
• Drive end‑to‑end project execution from concept through first article testing, commissioning, and production handover, managing budgets, and schedules.
• Champion Design for Manufacturability (DFM) and automation‑first approaches in collaboration with design, manufacturing, and quality teams.
• Implement Industry 4.0 capabilities including MES integration, machine vision, digital twins, predictive maintenance, and real‑time process monitoring.
• Establish and maintain standards for tooling design, controls architecture, documentation, and spare parts strategies to support 24/7 production operations.
• Manage vendor relationships for capital equipment, robotics, and controls hardware; negotiate contracts and lead equipment procurement.
• Mentor and develop engineers while fostering a culture of safety, innovation, and continuous improvement in a fast‑paced defense environment.

• Bachelor’s or Master’s degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Automation Engineering, or related field
• 5+ years in tooling, automation, and controls engineering for complex manufacturing.

• 10+ years in tooling, automation, and controls engineering for complex manufacturing.
• 5+ years in a leadership or people‑management role.
• Strong background in aerospace, defense, or energetic materials production environments.
• Expert‑level experience with industrial automation platforms (Rockwell, Beckhoff, Siemens), robotics (Fanuc, ABB, KUKA), and motion control systems.
• Proficient in 3D CAD (Solid Works / NX), automation design software, EPLAN / AutoCAD Electrical, and simulation tools.
• Deep knowledge of PLC programming, industrial networking (Ether
  
  CAT, Ether Net/IP), machine vision, and safety‑rated controls.
• Strong understanding of large‑scale composite manufacturing, propellant handling, and precision electromechanical assembly tooling.
• Experience scaling automation from prototype to high‑rate production.
• Leadership of tooling & automation programs for solid rocket motors, missiles, or hypersonic systems.
• Familiarity with ITAR, ATF, and DoD explosive safety standards.
• Proven people leadership and talent development skills.
• Strong project and program management capabilities with the ability to drive multiple…