Senior Mechanisms Engineer
Castelion Corporation•Rio Rancho, NM
•Onsite
About The Position
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
- U.S. citizenship is required
- Ability to obtain and maintain a U.S. government–issued security clearance
Responsibilities
- Design and develop mechanical actuation systems, including elevon drive trains and control surface mechanisms, for high-speed flight vehicles
- Lead the architecture and detailed design of mechanisms, including gear trains, linkages, bearings, and structural components
- Perform analysis of loads, stresses, deflections, and dynamic behavior to ensure performance and reliability under extreme environments
- Work closely with control electronics, GNC, avionics, and structures teams to ensure seamless integration of mechanisms with vehicle systems
- Conduct tolerance analysis, lubrication strategy development, and life/reliability assessments for high-duty-cycle systems
- Support prototyping, assembly, and hardware bring-up, including troubleshooting and root cause analysis of mechanism performance issues
- Define and execute qualification and environmental test plans, including vibration, thermal, and shock testing
- Optimize designs for mass, stiffness, reliability, and manufacturability
- Mentor junior engineers and contribute to best practices in mechanism design and analysis
- Partner closely with program leadership to make technical trades aligned with mission success
Benefits
- Meaningful long-term equity
- Four (4) weeks of paid time off
- Ten (10) company-paid holidays
- Comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage
- Dental plans
- Vision plans
- Paid parental leave
- $100 monthly fitness stipend
- Onsite EV charging
- Catered meals
- Company-covered food during high-demand periods
- Fully stocked kitchen
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What This Job Offers
Job Type
Full-time
Career Level
Senior
Education Level
Ph.D. or professional degree
