Senior Manufacturing Engineer - Composites

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we’re building a world-class team to turn bold ideas into real capability.

This is a rare opportunity to join at an early stage, where you’ll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.

Castelion is seeking a highly skilled Senior Manufacturing Engineer to establish in house manufacturing capability for composite components. This will include qualifying build processes, releasing mature work instructions, producing tooling, and training operators.

This role will be responsible for delivering flight ready composite hardware produced through internal Castelion manufacturing processes.

• Develop, validate, and implement manufacturing processes for composite structures, including layup, vacuum bagging, curing, trimming, bonding, and assembly operations.
• Design and develop production tooling, fixtures, molds, and manufacturing aids required for in-house production.
• Generate and release work instructions, process specifications, and manufacturing documentation.
• Troubleshoot manufacturing issues and drive improvements in quality, yield, throughput, and cost.
• Lead the transition of composite components from development and external suppliers to internal production.
• Establish process controls, manufacturing standards, and inspection requirements to ensure consistent product quality.
• Support equipment selection, factory development, and workflow optimization to enable efficient composite manufacturing.
• Partner with design and materials engineering teams to provide DFM feedback and ensure products are designed for manufacturability and production success.
• Support development, qualification, and implementation of new composite materials, tooling concepts, and manufacturing methods.
• Work cross-functionally with design, quality, supply chain, procurement, and program management to meet performance, schedule, and cost objectives.

• Bachelor’s or advanced degree in aerospace engineering, manufacturing engineering, materials engineering, mechanical engineering or physics.
• 3+ years of experience building aerospace grade composite components from scratch

• Experience in a hardware 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 composite components
• 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

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

This position may require access to classified information or…