Staff Mechanical Design Engineer

Castelion Corporation•Torrance, CA

27d

About The Position

Castelion is seeking a high-output Staff Mechanical Design Engineer with 8+ years of experience designing, analyzing, testing, and delivering flight hardware. This role is for a deeply technical engineer who can serve as a domain expert and technical leader while owning mission-critical hardware from concept through flight. The Staff Mechanical Design Engineer will develop expertise in an area such as mechanisms, structures, avionics packaging, or other mechanical systems, and will set a high bar for technical excellence across the team. This person will be expected to solve complex engineering problems independently, make sound design and analysis trade-offs, and mentor engineers to grow their technical capabilities.

Requirements

Bachelor's degree in Mechanical Engineering or related field.
8+ years of professional mechanical engineering experience.
Demonstrated experience taking complex hardware from concept through design, analysis, manufacturing, integration, test, and operation.
Deep expertise in at least one mechanical domain, such as mechanisms, structures, avionics packaging, or similar.
Expert-level CAD and mechanical design skills, including GD&T, tolerance analysis, materials, and manufacturability.
Strong understanding of structural mechanics, statics, vibration, and FEA.
Experience designing high-performance hardware with constraints on mass, cost, schedule, reliability, and manufacturability.
Strong hands-on problem-solving skills and experience working directly with hardware.

Nice To Haves

Nonlinear FEA, including contact, material nonlinearity, or large deformation.
Experience correlating analytical models with physical test data.
Aerospace, hypersonic, launch vehicle, spacecraft, or other high-performance flight hardware experience.
Experience establishing engineering standards or methodologies.
Demonstrated ability to mentor and develop engineers technically.
Experience working with composites, coatings, finishes, and advanced manufacturing processes.

Responsibilities

Lead the design, analysis, build, integration, and test of critical flight hardware from concept through flight.
Serve as a technical authority in a mechanical domain such as mechanisms, structures, or avionics packaging. Establish and maintain high standards for design, analysis, manufacturability, and flight readiness.
Perform and/or lead structural analysis using first-principles engineering, FEA, statics, vibration, and modal analysis.
Drive high-cadence design iterations, incorporating test results and lessons learned into rapid hardware improvements.
Work directly with technicians, manufacturing, suppliers, and test teams to troubleshoot hardware and drive problems to closure.
Mentor engineers through design reviews, technical problem-solving, and hands-on coaching. Raise the technical capability and engineering standards of the broader team.
Improve CAD, analysis, documentation, hardware development, and design practices while maintaining speed and technical discipline.