Principal Build Reliability Engineer

Why Castelion, Why Now Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability. This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function. Why Castelion, Why Now Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts. This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact. Principal Build Reliability Engineer Castelion is seeking a Build Reliability Engineer to ensure the reliability of flight components and assemblies. This individual will evaluate product and process output data to drive improvements in manufacturing quality and actively represent quality objectives in design and development teams. Responsibilities • This individual will evaluate product and process output data to drive improvements in manufacturing quality, and actively represent quality objectives in design and development teams • Design for Manufacture • Participating in Preliminary Design Review (PDR) / Critical Design Review (CDR) to ensure design for quality (DFQ), design for manufacturability (DFM), risk quantification and mitigation, and that appropriate test validation methods and inspection techniques, including nondestructive evaluation methods, have been considered • Hands-on development of design for manufacturability through ensuring identification of key characteristics, prototype testing for manufacturability, First Article and Detailed Inspection planning, evaluation of previous non-conformances and lessons learned, and other manufacturing and quality tools as required • Inspection and Test Process Development • Leads inspection planning for new products through identification of features and gages, and integration with planned operations • Designs or procures new measurement methods as required and integrates with existing processes • Validates new and existing measurement and tests methods using process capability and measurement systems analysis (MSA) statistical tools • Propose solutions to remove the need to verify product conformance through measurement, e.g. poka-yoke • First Build Reviews and Walk downs • Co-ordinates, schedules and facilitates objective First Build Reviews to ensure transparency of design intent, design requirements, design and manufacturing risks, and manufacturability of design • Develop and maintains engineering walk down criteria for major product milestones to provide clear guidance to Production on engineering intent and acceptance criteria • Identifies photo closeout requirements for complete as-built documentation • Evaluates and analyzes production quality landscape • Uses data to make landscape transparent and drive project prioritization • Responsible for ensuring that issues related to product reliability are primary focus • Drives achievement of quality targets through a review hierarchy with appropriate levels of management • Ensure controls in place to prevent recurrence • Root Cause and Corrective Action Investigations • Leads, facilitates, and participates in root cause investigations in their respective area • Deep dives using appropriate quality or analysis tools as required • Ensures documentation of cause and corrective action is captured appropriately • Ensures appropriate actions to prevent recurrence • Containment • Leads activity to support containment of all suspect products • Provides guidance to quality inspectors, techs, and shop supervisors to assist in quarantining of all suspected products • Communicate status of evaluation and disposition to production leadership on a regular basis • Issue Ticket Review/Audit/Closure • Supports review of all issue tickets in respective areas • Ensures rationale and documentation of design deviation is captured • Leads and coordinates the management of non-conforming hardware • Review of Engineering Masters (EM), Work Order (WO) instructions and drawings • Reviews and approves Engineering Orders (EO's), Engineering Masters (EM's), Work Orders (WO's), specifications, and product introduction and documentation for completeness, accuracy, regulatory compliance, and quality objectives • Validates that drawing captures all requirements needed to build and inspect hardware • Develop Inspection plans and modifies as required for process or design changes • Ensures inspection/test criteria are objective with clear pass/fail criteria • Production Process Audit/Improvement • Assesses new processes for safety and product risks • Ensures adherence to QMS policy and procedures within their work center • Develop criteria and builds audits to identify process weaknesses Basic Qualifications • Bachelor's or advanced degree in aerospace engineering, manufacturing engineering, materials engineering, mechanical engineering or physics. • Minimum 5+ years in a quality, manufacturing, or design engineering role Preferred Skills and Experience • Experience supporting production of complex electro-mechanical, mechanical, or composites systems in high volume work centers and/or during production ramp-up. • Knowledge of quality tools such as Lean principles, Six Sigma, Root Cause Analysis and Corrective Action, Advanced Product Quality Planning (APQP), Metrology, Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and various problem-solving approaches. • Dedicated to adopting a Lean approach to quality without compromising safety or reliability. Benefits And Perks • Employee Equity: Meaningful equity for all full-time employees - share value has increased 150x in three years • Personal Time Off: Four (4) weeks of paid time off to unplug, reset, and come back sharp—velocity matters, burnout doesn't • Company Paid Holidays: Ten (10) company paid holidays • Medical: We offer plans at 100% employee covered and 80% of dependent coverage • Dental & Vision: We cover 90% employees and 80% for dependents to ensure you and your family have access to quality preventive and ongoing care • FSA/HSA: To support long-term health and financial resilience, we offer FSA and HSA options that allow employees to set aside pre-tax dollars for eligible medical and dependent care expenses • Retirement: 401k plan offered to support long term financial growth along side high-impact, high-velocity work • Paid Parental Leave: We support growing families with meaningful time to bond and recover. Birthing parents are eligible for up to 10 weeks of paid leave, while non-birthing parents may take up to 4 weeks of paid leave. This time can be used for pre-natal care, pregnancy, childbirth, and related medical needs—ensuring every parent has the support they need during this important life moment.8-weeks of paid parental leave for all parents. Additional paid pregnancy leave for CA employees • Meals & Catering: Frequently catered lunches and team meals, plus company-covered meals when extra time or effort is required • Snacks & Beverages: Fully stocked kitchen with unlimited snacks and drinks to keep you fueled throughout the day • Performance & Fitness: $100 monthly fitness stipend to support peak performance and health, both inside and outside of work • EV Charging: Onsite electric vehicle charging available for employees Physical Demands • Must be willing to work extended hours and/or weekends