Senior Structures & Composites Engineer (Rocket Motor Cases)

Castelion Corporation•Rio Rancho, NM

About The Position

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
U.S. citizenship is required

Nice To Haves

Ability to obtain and maintain a U.S. government–issued security clearance

Responsibilities

Design and develop rocket motor case structures, including composite overwrapped pressure vessels (COPVs) and filament-wound composite cases
Lead the architecture and detailed design of motor cases, including load paths, interfaces, domes, bosses, and attachment features
Perform structural analysis of pressure vessels under internal pressure, thermal loads, and dynamic environments to ensure performance and reliability
Develop and analyze composite layups, fiber orientations, and manufacturing approaches to optimize strength, stiffness, and mass
Work closely with propulsion, materials, manufacturing, and test teams to ensure seamless integration of motor cases with propulsion systems
Support material selection, processing, and characterization for composite and high-temperature materials
Conduct failure analysis and root cause investigations, driving design improvements and risk reduction
Define and execute qualification and environmental test plans, including pressure testing, proof/burst testing, and vibration testing
Support prototyping, fabrication, and hardware bring-up, including troubleshooting manufacturing and structural performance issues
Optimize designs for mass efficiency, manufacturability, and operational reliability
Mentor junior engineers and contribute to best practices in composite and pressure vessel design
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