Manufacturing Engineer Jobs

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About The Position

Castelion is seeking a Senior Manufacturing Engineer to own sheet metal forming and welding processes for Castelion’s solid rocket motor and hypersonic vehicle hardware. This role is responsible for developing, qualifying, and scaling fabrication of formed and welded metallic structures. You will define forming methods, weld processes, fixtures, inspection, and production flow while partnering with Design, Quality, Tooling & Automation, and Operations. The objective is repeatable, flight-quality metallic hardware from development builds through high-rate production.

Requirements

  • Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
  • 6–10+ years of manufacturing engineering experience in aerospace, defense, or high-reliability metallic fabrication.
  • 3+ years of hands-on ownership of sheet metal forming and welding processes on flight or mission-critical hardware.
  • Demonstrated success qualifying fabrication processes and transitioning them from development to production.
  • Strong practical knowledge of sheet metal forming (brake, roll, stretch, hydroform, or equivalent) and fusion welding processes used in aerospace production.
  • Proficiency in CAD (SolidWorks or NX), GD&T, tolerance stack-up, and fixture concepting.
  • Working knowledge of weld procedure development, distortion control, fit-up, and post-weld heat treatment or finishing as applicable.
  • Experience with PFMEA, SPC, root-cause methods (8D, fishbone), and process qualification.
  • Familiarity with metrology and NDE of formed and welded structures.
  • Ability to write clear work instructions and support shop-floor execution.
  • Hands-on, detail-oriented, and effective at enforcing process discipline on the shop floor.
  • Strong collaboration with Design, Quality, Tooling, and Operations teams.
  • Clear technical communication and documentation skills.
  • Data-driven problem solver under schedule pressure.
  • Safety-first mindset when working in facilities that handle energetic materials.

Nice To Haves

  • Direct manufacturing experience on missile, rocket-motor, or aerospace structural metallic hardware.
  • Background in fast-paced defense or space production environments.
  • Experience with robotic or automated welding and forming cells.
  • Prior work on stainless, high-strength steels, nickel alloys, aluminum, or other aerospace alloys used in propulsion or vehicle structures.
  • Familiarity with AS9100, ITAR programs, and manufacturing in energetic-materials facilities.
  • Track record reducing scrap, rework, distortion, or cycle time on welded or formed flight hardware.

Responsibilities

  • Own manufacturing processes for sheet metal forming and welding, including cutting, bending, rolling, hydroforming or equivalent forming methods, fit-up, welding, post-weld processing, and final inspection.
  • Develop and qualify weld procedures, forming processes, fixtures, and work instructions that meet dimensional, structural, and quality requirements.
  • Execute DFM/DFA, PFMEA, control plans, and statistical process control (SPC) to improve first-pass yield, cycle time, and cost.
  • Define inspection and NDE strategies for formed and welded hardware (dimensional inspection, visual weld inspection, and approved NDE methods).
  • Partner with Tooling, Automation & Controls on forming dies, weld fixtures, positioners, and semi-automated or robotic welding cells.
  • Support new product introduction and design changes with producibility input on material selection, bend radii, weld joint design, tolerances, and assembly sequence.
  • Lead root-cause analysis and corrective actions for forming defects, weld defects, distortion, fit-up issues, and dimensional escapes.
  • Author and maintain travelers, WPS/PQR support documentation as applicable, and quality records compliant with AS9100 and customer requirements.
  • Collaborate with suppliers on sheet stock, formed details, and welded subassemblies; drive incoming quality and process capability.
  • Support equipment qualification and production ramp in Torrance, CA and the Project Ranger campus in New Mexico.

Benefits

  • generous benefits package

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