Lead Integration & Test Engineer Castelion is bringing a new approach to defense development and production: short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production at scale. The company is designing, building, and testing next-generation long-range strike weapons systems to give America and its allies a definitive edge and deter future conflicts. Castelion is looking for a Lead Integration & Test Engineer with deep expertise in the integration and verification of warhead systems into complete hypersonic missile vehicles. You will own end-to-end I&T strategies from subassembly through full vehicle level, supporting ground qualification, environmental testing, and flight test campaigns for next-generation hypersonic strike weapons. You will serve as the technical authority on warhead-vehicle integration and test, collaborating closely with design, manufacturing, propulsion, radar, quality, and mission assurance teams to meet stringent DoD standards and mission requirements. Key outcomes for 2026 include delivering a production-ready I&T process in Rio Rancho, New Mexico; developing a scale plan from LRIP to thousands of units per year; supporting a rapid flight test cadence; and building the integration and test engineering team that can independently support future facility development and production execution.
What You'll Do:- Lead warhead-to-vehicle integration activities including mechanical mating, electrical interface verification, fuze and S&A installation, and safe separation testing
- Develop and execute comprehensive vehicle-level I&T plans covering functional checkout, ordnance arming sequences, environmental qualification, and system verification
- Design and commission integration tooling, test fixtures, and automated test equipment for warhead handling and full missile assembly
- Oversee environmental stress screening (thermal, vibration, shock, EMI/EMC) and functional performance testing of integrated warhead-vehicle systems
- Support flight test preparation, range coordination, pre-flight checkout, and post-flight data analysis and anomaly resolution
- Perform root-cause investigations and corrective actions for integration and test anomalies using FRACAS and fault tree analysis
- Ensure full compliance with explosive safety standards, DoD 6055.09, MIL-STD-810, and mission assurance requirements
- Mentor I&T engineers and lead cross-functional teams during build and test campaigns
- Drive continuous improvement in integration processes, test automation, and digital thread implementation for faster iteration cycles
- You Should Have 8+ years of experience in integration and test for complex aerospace or defense systems 4+ years specifically working with warheads, munitions, or energetic systems integration
- Demonstrated leadership of vehicle-level integration and test campaigns, preferably on missile or hypersonic programs
- Strong experience with ordnance handling, safe-and-arm devices, and energetic materials integration
- Proficiency in test automation using LabVIEW, Python, or MATLAB, plus data acquisition systems and telemetry
- Hands-on experience with environmental testing and ordnance functional verification
- Experience with requirements management, configuration control, and 3D CAD for integration planningU.S. citizenship or permanent resident status required (ITAR)
- Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, Systems Engineering, or a related field
Nice to Have:- Direct experience on DoD missile or hypersonic warhead programs
- Background in fast-paced development environments
- Knowledge of insensitive munitions and advanced warhead designs
- Prior flight test support at ranges
- Experience with classified programs and TS/SCI level work
Compensation and Benefits:
Long-term stock incentives for all employees. Comprehensive medical, vision, and dental insurance, plus four weeks of paid time off per year.
