Senior Manufacturing Engineer, Igniters and Pyrotechnics

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. Senior Manufacturing Engineer Igniters and Pyrotechnic Devices – Aerospace & Defense About Castelion Castelion is building affordable, rapidly producible hypersonic strike weapons for the U.S. military. We move quickly from design to flight test to production, and we are standing up high-rate manufacturing at our facility in Midland, Texas and our Project Ranger campus in New Mexico. Position Overview We are seeking a Senior Manufacturing Engineer to own manufacturing processes for igniters and pyrotechnic devices supporting Castelion’s hypersonic strike weapons, including the Blackbeard program. This role focuses on developing, optimizing, qualifying, and executing production processes for solid rocket motor igniters, initiators, gas generators, and other pyrotechnic devices. You will drive process improvements, lead the transition from prototype and research builds to scalable high-rate production, and ensure products are high quality and manufactured safely and efficiently. You will work closely with Design, Automation & Controls, Quality, Test, and fellow Manufacturing Engineers to ensure your products integrate with the larger system, and you will contribute to new product introduction, continuous improvement, and facility ramp-up at our manufacturing sites. What You’ll Accomplish in Your First 12 Months • Establish safe, repeatable manufacturing processes for igniters and pyrotechnic devices, with process specifications, work instructions, and explosives SOPs in place. • Define and qualify the tooling and equipment needed for both R&D and production-scale manufacturing. • Deliver, and begin executing, a plan to scale from low-rate initial production to full-rate production of thousands of units per year. Key Responsibilities • Own development and optimization of igniter and pyrotechnic manufacturing processes, including piece part manufacturing, pyrotechnic composition weighing, blending, and pressing/consolidation, device assembly, and sealing (including hermetic sealing). • Drive Design for Manufacturability (DFM), Design for Assembly (DFA), PFMEA, control plans, and statistical process control (SPC) to improve yield, reduce cycle time, and lower cost. • Author explosives operating procedures (SOPs) and support process hazard analyses, hazard classification, and explosives site planning for new and modified operations. • Implement electrostatic discharge (ESD) controls and safe handling practices for initiators, bridgewire devices, and other electrically sensitive components. • Define and execute inspection and acceptance strategies in partnership with Quality and Test, including radiographic inspection (X-ray/N-ray), bridgewire resistance testing, lot acceptance testing, and closed-bomb testing. • Support new product introduction (NPI) and design change implementation by providing manufacturing input and executing first article inspections and process qualifications. • Perform root-cause analysis and lead corrective/preventive actions for process issues and defects. • Collaborate with Automation & Controls to implement robotics, vision systems, and digital tools (MES, data analytics) for improved efficiency and traceability. • Author and maintain work instructions, process documentation, and training materials; document and disposition nonconformances; mentor junior manufacturing engineers. • Ensure compliance with explosives safety and regulatory requirements, including DoDM 4145.26, DESR 6055.09, DOT hazardous materials regulations (49 CFR), and ITAR. • Support equipment qualification, process validation, and production ramp at the Midland, TX facility and the Project Ranger campus in New Mexico. • Interface with suppliers on materials, tooling, and equipment to resolve issues and improve incoming quality. Required Qualifications Education: Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Materials Science, or related field. Experience: • 7+ years of manufacturing engineering experience, including 3+ years of hands-on work processing energetic materials or manufacturing igniters, initiators, or other pyrotechnic devices in aerospace or defense. • Demonstrated success developing and scaling manufacturing processes from prototype to low-rate or rate production. Technical Skills: • Hands-on experience building, inspecting, and accepting complex electromechanical and energetic assemblies. • Proficiency in CAD (SolidWorks or NX), GD&T, tooling/fixture design, process documentation, and nonconformance disposition. • Working knowledge of explosives safety requirements, hazard analysis, and hazardous process manufacturing. Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details. Other Duties Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice. Additional Eligibility Requirements This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply. Affirmative Action/EEO Statement Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law. Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact hr@castelion.com. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law. Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation. EAR/ITAR Requirements This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.