Senior Warhead Design Engineer

Job Description About Castelion Castelion is bringing a new approach to defense development and production: one that focuses on short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production at scale. We are designing, building, and testing next-generation long-range strike weapons systems to give America and its Allies a definitive edge and deter future conflicts. Senior Warhead Design Engineer Castelion is designing and building next-generation hypersonic weapon systems that restore stability through credible deterrence. We are seeking a hands-on, mission-driven Senior Warhead Design Engineer to lead the design, development, and integration of ordnance systems across our hypersonic vehicles. This is a high-impact role for someone with deep expertise in energetic devices and safe & arm mechanisms, who thrives in a fast-paced, hardware-rich development environment. Responsibilities Own the design, development, and qualification of ordnance systems, including: Initiators, detonators, transfer charges, explosive bolts, safe & arm devices. Mechanically or electronically actuated flight termination systems (FTS). Define requirements and interface specifications across mechanical, electrical, and software boundaries. Lead supplier engagement, component selection, and build-to-print efforts with a focus on manufacturability, cost, and performance. Drive development test planning, execution, and analysis for ordnance systems (including arena testing, function testing, and environmental qualification). Work closely with systems, propulsion, and GNC teams to ensure ordnance components integrate safely and effectively into the full weapon system. Support FMEA, fault-tree analysis, and safety case development. Own documentation and compliance to MIL-STD-1901A, AFSPCMAN 91-710, and other relevant standards. Basic Qualifications B.S. or M.S. in Mechanical Engineering, Aerospace Engineering, or related field. 5+ years of experience in ordnance or energetics design, analysis, and test. Deep understanding of flight termination systems, safe & arm devices, and energetic component integration. Familiarity with relevant DoD and NASA standards (e.g., MIL-STD-1901A, RCC 319, etc.). Hands-on test experience in high-consequence environments. Strong communication and documentation skills. Active or eligible for a U.S. security clearance. Skills and Experience Experience working with DoD customers and navigating military qualification processes. Background in hypersonics, missile systems, or space launch vehicles. CAD and mechanical analysis experience (e.g., SolidWorks, FEA tools). Prior experience working at a defense startup or fast-moving development organization. Leadership Qualities Bias to Action and Creative Problem Solving.

Desire and experience questioning assumptions in ways that lead to breakthrough ideas that are ultimately implemented. Successfully bring in applicable processes, concepts, or materials from other industries to achieve efficiency gains. Ability to personally resolve minor issues in development without requiring significant support. High Commitment, High Initiative.

A successful candidate will have a genuine passion for Castelion's mission and consistently look for ways to contribute to the company's technical goals and prevent hardware blockers. Ability to work in a fast-paced, autonomously driven, and demanding atmosphere. Strong sense of accountability and integrity. Clear Communicator.

Proactively communicates blockers. Trusted in previous roles to be the voice of the company with regulators, suppliers, gatekeepers, and customers. Capable of tactfully managing relationships with stakeholders to achieve company-desired outcomes without compromising relationships. Emails, IMs, and verbal interactions are logical, clear, and detailed enough to eliminate ambiguity. ITAR Requirements To conform to U.S. Government export regulations, applicants must be U.S. citizens, U.S. lawful permanent residents (green card holders), refugees under 8 U.S.C. § 1157, or asylees under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Employment with Castelion is based on competence and qualifications and will not be influenced by protected statuses. All employees are granted long-term stock incentives, comprehensive medical, vision, and dental insurance, and four weeks of paid time off per year.

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