Senior Mechanisms Engineer

STEM Boomerang•Rio Rancho, NM

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, we combine rapid iteration, vertical integration, and scalable manufacturing to deliver affordable, high-performance strike systems. Our mission: rebuild industrial agility to strengthen national security and outpace evolving threats. We are seeking a Senior Mechanisms Engineer to design and deliver high-performance mechanical actuation systems for Castelion's long-range hypersonic strike vehicles. This role is critical to enabling precise and reliable control surface motion and deployment mechanisms under extreme flight conditions. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate mechanisms such as elevon drive trains and related actuation systems in a fast-paced, hardware-driven environment.

Requirements

Bachelor's, Master's, or PhD in Mechanical Engineering or related field
5+ years of experience in mechanism design, analysis, and validation for aerospace or high-performance mechanical systems
Strong background in gear trains, actuation systems, and precision mechanical design
Experience designing electromechanical actuators (EMAs) for aerospace or similarly demanding applications
Familiarity with motor-driven actuation systems, including motor selection, gear reduction, torque transmission, and position feedback mechanisms
Experience designing control surface drive systems or similar high-load, high-reliability mechanisms
Proficiency in CAD and analysis tools (e.g., 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, thriving in a fast-paced, hardware-rich, high flight cadence environment

Responsibilities

Design and deliver high-performance mechanical actuation systems for long-range hypersonic strike vehicles.
Design, analyze, build, and validate mechanisms such as elevon drive trains and related actuation systems.
Work hands-on with multidisciplinary engineering teams.
Operate in a fast-paced, hardware-driven environment.

Benefits

Meaningful equity for all full-time employees
Four (4) weeks of paid time off
Ten (10) company paid holidays
Medical plans at 100% employee covered and 80% of dependent coverage
Dental & Vision: 90% employees and 80% for dependents
FSA/HSA options
401k plan
Paid Parental Leave: Up to 10 weeks for birthing parents, up to 4 weeks for non-birthing parents. Additional paid pregnancy leave for CA employees.
Frequently catered lunches and team meals
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