Senior Test Engineer, Solid Rocket Motors & Hypersonic Systems

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 Senior Test Engineer to lead testing activities for solid rocket motors (SRM) and integrated hypersonic strike vehicles s role is responsible for developing and executing test plans for static fire testing, environmental qualification, functional verification, and flight test support.

You will work hands-on with propulsion hardware, instrumentation, data acquisition systems, and test infrastructure while ensuring the highest standards of safety, data quality, and mission success. Partnering closely with Propulsion, Manufacturing, Integration & Test, and Design teams, you will drive test readiness for prototype, qualification, and production hardware on aggressive development timelines for programs like Blackbeard.

• Lead the development of comprehensive test plans, procedures, and requirements for SRM static fires, environmental testing (vibration, thermal, shock, humidity), functional checkout, and vehicle-level integration testing.
• Design, commission, and operate test fixtures, instrumentation setups, and data acquisition systems for thrust, pressure, temperature, vibration, and other critical parameters.
• Execute and oversee static fire tests, environmental stress screening, and other qualification tests, ensuring safe operations with energetic materials and high-consequence hardware.
• Perform real-time test monitoring, data reduction, analysis, and reporting; identify anomalies and lead root-cause investigations with cross-functional teams.
• Support flight test campaigns, including pre-flight checkout, range coordination, telemetry monitoring, and post-flight data analysis.
• Drive continuous improvement in test processes, safety protocols, and efficiency while integrating automation and digital tools for data capture and analysis.
• Collaborate with Manufacturing and Propulsion on testability, design-for-test feedback, and hardware maturation from prototype to rate production.
• Author and maintain test documentation, safety plans, and compliance records in accordance with DoD, range safety, and energetic materials standards.
• Mentor junior test engineers and contribute to building robust test capabilities at Castelion facilities and partner ranges.
• Manage test schedules, resources, and interfaces with internal teams, suppliers, and external test ranges.

• Bachelor’s Aerospace Engineering, Systems Engineering, or related field
• 5 years of engineering test experience for solid rocket motors

• Master’s degree in Mechanical Engineering, Aerospace Engineering, Systems Engineering, or related field.
• 6-10+ years of test engineering experience in aerospace or defense, with at least 3+ years focused on propulsion, solid rocket motors, or missile systems testing.
• Proven track record developing and executing complex test programs from component through system level, including energetic or hazardous testing.
• Strong hands-on experience with test instrumentation, data acquisition (e.g., LabVIEW, MATLAB, or similar), sensors (pressure transducers, accelerometers, thermocouples), and high-speed data systems.
• Proficiency in test stand design, fixture development, and environmental test equipment (shakers, thermal chambers, etc.).
• Experience with static fire testing, thrust measurement, and ballistic performance evaluation for solid rocket motors.
• Working knowledge of safety protocols for energetic materials, ordnance handling, and high-pressure systems.
• Familiarity with telemetry, flight test operations, and post-test data analysis tools.
• Direct experience with solid rocket motor static fire testing or hypersonic propulsion testing on DoD…