Mechanisms Engineer (Castelion)

STEM Boomerang•Rio Rancho, NM

10h

About The Position

Castelion was founded to restore America’s ability to field advanced weapons at speed and scale. Inspired by the engineering urgency of the WWII and Apollo eras, the company combines rapid iteration, vertical integration, and scalable manufacturing to deliver affordable, high-performance strike systems. Its mission is to rebuild industrial agility to strengthen national security and outpace evolving threats. Castelion is seeking a Senior Mechanisms Engineer to design and deliver thrust vector control (TVC) actuation systems for long-range hypersonic strike vehicles. The role supports precise, high-bandwidth thrust vectoring in extreme dynamic and thermal environments. The engineer will work hands-on with multidisciplinary teams to design, analyze, build, and validate TVC actuators and associated mechanisms in a fast-paced, hardware-driven environment.

Requirements

Bachelor’s, Master’s, or PhD in Mechanical Engineering or a related field.
At least 5 years of experience in mechanism and actuator design for aerospace or high-performance dynamic systems.
Strong background in electromechanical actuators (EMAs), including motor-driven systems, gear reduction, and torque transmission.
Experience designing high-load, high-bandwidth actuation systems such as TVC, control surface actuation, or similar applications.
Familiarity with motor selection (e.g., BLDC), position sensing (encoders/resolvers), and actuator feedback integration.
Proficiency in CAD and analysis tools such as NX, SolidWorks, ANSYS, or equivalent.
Experience with structural analysis, fatigue/life assessment, and tolerance stack-up analysis.
Familiarity with high-temperature materials, lubrication strategies, and operation in extreme environments.
Experience with hardware build, test, and troubleshooting in a lab or flight hardware environment.
Strong problem-solving mindset and ability to thrive in a fast-paced, hardware-rich, high flight cadence environment.

Responsibilities

Design and deliver thrust vector control (TVC) actuation systems for long-range hypersonic strike vehicles.
Design, analyze, build, and validate TVC actuators and associated mechanisms.
Support precise, high-bandwidth thrust vectoring in extreme dynamic and thermal environments.
Work hands-on with multidisciplinary engineering teams.

Benefits

Meaningful equity for all full-time employees.
Four weeks of paid time off.
Ten company-paid holidays.
Medical plans with 100% employee coverage and 80% dependent coverage.
Dental and vision coverage with 90% employee and 80% dependent coverage.
FSA and HSA options.
401(k) plan.
Paid parental leave, including up to 10 weeks for birthing parents and up to 4 weeks for non-birthing parents; the posting also states eight weeks of paid parental leave for all parents and additional paid pregnancy leave for California employees.
Frequently catered lunches and team meals, plus company-covered meals when extra time or effort is required.
Fully stocked kitchen with unlimited snacks and drinks.
$100 monthly fitness stipend.
Onsite electric vehicle charging.