Avionics Manufacturing Engineer, Electrical Integration

Castelion Corporation•Torrance, CA

About The Position

Castelion is hiring an Avionics Manufacturing Engineer focused on Electrical Integration to support the development and production of systems for long-range hypersonic strike vehicles. Reporting to the Lead Manufacturing Engineer of Avionics, this role develops and improves manufacturing processes for integrating printed circuit board assemblies (PCBAs), electrical components, and interconnects into mechanical housings and higher-level avionics assemblies. The position combines knowledge of electrical hardware, mechanical assembly, and manufacturing process control. The engineer will create work instructions and establish process controls to ensure avionics assemblies are built safely, correctly, and repeatably. The role partners with other engineering teams on tooling, automation, inspection methods, and production testing, and translates electrical, mechanical, thermal, and environmental requirements into practical manufacturing processes. The position may be based at Castelion’s Allen, Texas, or Torrance, California facility, and requires travel up to 25% and willingness to work extended hours and/or weekends as needed. The position may require access to classified information or restricted U.S. Government sites, systems, or information. If designated, employment may depend on obtaining and maintaining required security clearance or government authorization and meeting applicable citizenship or other eligibility requirements. The role also requires access to export-controlled information, without additional export licensing being required.

Requirements

Bachelor’s degree in electrical, mechanical, manufacturing, aerospace engineering, or a related technical field.
At least 3 years of experience in avionics, electronics, electrical integration, electro-mechanical assembly, or high-reliability manufacturing.
Hands-on experience integrating PCBAs or electrical components into mechanical assemblies.
Experience developing manufacturing processes, work instructions, inspection criteria, or process controls.
Ability to read electrical schematics, PCBA drawings, mechanical drawings, and manufacturing documentation.
Strong hands-on troubleshooting, communication, and technical problem-solving skills.
Willingness to work extended hours and/or weekends as needed.
Ability to travel up to 25% of the time.
Ability to access applicable export-controlled information without additional export licensing being required.

Nice To Haves

Experience manufacturing or integrating flight avionics, defense electronics, automotive electronics, or other high-reliability hardware.
Experience with thermal interface materials, gap fillers, thermal pads, adhesives, gaskets, environmental seals, fasteners, and grounding features.
Experience supporting the development of manufacturing tooling, fixtures, automation, or production test equipment.
Experience with process validation and manufacturing acceptance criteria.
Familiarity with GD&T, tolerance stack-ups, mechanical fits, fastener torque, and electro-mechanical assembly processes.
Experience with electrical continuity, grounding, hipot, insulation resistance, or functional testing.
Working knowledge of IPC-A-610, IPC/WHMA-A-620, or similar workmanship standards.
Experience supporting both development and production hardware in a fast-paced aerospace or defense environment.

Responsibilities

Develop and improve manufacturing processes for integrating PCBAs and electrical components into mechanical housings and higher-level avionics assemblies.
Write work instructions, visual aids, assembly procedures, and inspection criteria for avionics hardware.
Establish process controls for installing PCBAs, thermal interface materials, gaskets, fasteners, connectors, grounding features, and electrical interconnects.
Define and validate critical assembly parameters, including material placement, surface preparation, fastener torque, tightening sequence, compression, alignment, and cleanliness.
Partner with Design, Test, and Manufacturing Engineering to develop tooling, fixtures, automation, inspection methods, and production test equipment.
Review electrical schematics, PCBA drawings, mechanical drawings, bills of material, and assembly documentation to determine manufacturing requirements.
Provide manufacturability feedback on assembly sequence, component access, connector routing, grounding, thermal management, tolerance stack-up, tooling access, and test access.
Troubleshoot electrical and electro-mechanical assembly issues and support root-cause investigations and corrective actions.
Support technicians during development and production builds and train them on new or improved manufacturing processes.
Support the transition of avionics hardware from development builds into controlled, repeatable production.
Partner with Design Engineering, Test Engineering, Quality, Planning, Supply Chain, and Production to resolve manufacturing issues.
Improve first-pass yield, assembly time, workmanship, production flow, and process repeatability.