Senior Structures & Composites Engineer (Rocket Motor Cases)

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. About the Role: We are seeking a Senior Structures & Composites Engineer to design and deliver high-performance rocket motor cases for Castelion's long-range hypersonic strike vehicles. This role is critical to enabling lightweight, high-strength propulsion structures capable of withstanding extreme pressure and thermal environments. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate composite and metallic motor case structures in a fast-paced, hardware-driven environment.

Requirements

Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, or related field
5+ years of experience in structural and composite design for aerospace or high-performance pressure vessel applications
Strong background in composite materials, including filament winding, laminate theory, and failure criteria (e.g., Tsai-Wu, Hashin)
Experience designing pressure vessels, COPVs, or rocket motor cases for high-pressure applications
Proficiency in structural analysis tools (e.g., ANSYS, Abaqus, NASTRAN, or equivalent)
Familiarity with manufacturing processes for composites, including winding, curing, and inspection methods (e.g., NDI/NDT)
Experience with proof/burst testing and structural validation of pressure vessels
Experience with hardware build, test, and troubleshooting in a lab or production environment
Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high test cadence environment

Responsibilities

Design and deliver high-performance rocket motor cases for Castelion's long-range hypersonic strike vehicles.
Design, analyze, build, and validate composite and metallic motor case structures.
Work hands-on with multidisciplinary engineering teams.

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