Manufacturing Engineer – Composite Motor Cases

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.

The Manufacturing Engineer – Composite Motor Cases will own the development, industrialization, and production of manufacturing processes used to build advanced composite solid rocket motor cases.

This is a highly hands‑on role supporting the transformation of filament-wound composite structures and associated components into completed motor‑case assemblies. Depending on experience and program needs, engineers in this role may own processes including insulation and rubber application, bonding, cure, hardware integration, assembly, tooling, or other composite motor‑case manufacturing operations.

You will work closely with Filament Winding, Design, Materials, Quality, Propulsion, and Production teams to develop robust manufacturing processes and transition hardware from development into repeatable production.

• Establish robust and repeatable manufacturing processes for composite motor cases.
• Develop qualified tooling, manufacturing methods, and process controls for assigned motor‑case operations.
• Transition composite motor‑case manufacturing processes from development into stable production.
• Improve manufacturing capability, quality, cycle time, and scalability as production demand increases.

• Own manufacturing processes within the composite motor‑case production flow.
• Develop and optimize bonding, cure, integration, assembly, and material application processes.
• Develop tooling, fixtures, work instructions, routings, and process controls.
• Support insulation, rubber, adhesives, and other material systems used in composite motor‑case manufacturing.
• Integrate filament‑wound structures and associated hardware into completed motor‑case assemblies.
• Lead process qualification and production‑readiness activities.
• Partner with Filament Winding, Design, and Materials Engineering to ensure manufacturability and robust processing.
• Partner with Quality to establish inspection requirements and process controls.
• Lead root‑cause investigations and resolve manufacturing issues.
• Develop capacity and production scaling plans for assigned processes.
  
  Support supplier development and outsourced manufacturing as needed.
• Provide hands‑on support to technicians during development and production builds.

• B.S. in Mechanical, Aerospace, Manufacturing, Materials Engineering, or related field.
• Experience in manufacturing engineering or production of complex hardware.
• Experience developing and improving manufacturing processes.
• Ability to develop tooling, work instructions, and process controls.
• Demonstrated ability to solve manufacturing problems in a hands‑on production environment.

• Experience with composite structures, aerospace, defense, or propulsion manufacturing.
• Experience with bonded assemblies, adhesives, rubber, insulation, cure, or structural integration.
• Experience taking composite hardware or manufacturing processes from development into production.
• Experience with manufacturing tooling, process qualification, or production scaling.
• Experience working across multidisciplinary engineering and production teams.

Castelion offers a generous benefits package. Please…