Senior Thermal & TPS Integration 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. About the Role: We are seeking multiple Senior Thermal & TPS Integration Engineers to design and deliver thermal protection solutions for Castelion's long-range hypersonic strike vehicles. These roles are critical to ensuring vehicle survivability and performance in extreme aerothermal environments. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate TPS across the vehicle, including heat shields, control surface protection, and internal thermal insulation systems in a fast-paced, hardware-driven environment.

Requirements

Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field
5+ years of experience in thermal protection system design, analysis, and validation for aerospace or high-temperature applications
Strong background in aerothermal environments, heat transfer, and high-temperature materials
Experience designing TPS for flight vehicles, including heat shields, control surfaces, or internal insulation systems
Familiarity with TPS materials such as ceramics, carbon-carbon, ablatives, and insulating blankets
Experience with seals, gaps, and interface design in high-temperature, moving or constrained systems
Proficiency in thermal and structural analysis tools (e.g., ANSYS, MATLAB, or equivalent)
Experience with high-temperature testing methods (e.g., arc-jet, furnace, or similar)
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 thermal protection solutions for long-range hypersonic strike vehicles.
Ensure vehicle survivability and performance in extreme aerothermal environments.
Work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate TPS across the vehicle.
Design heat shields, control surface protection, and internal thermal insulation systems.

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% for 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