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. We are seeking a Lead Integration & Test Engineer with deep expertise in the integration and verification of complete hypersonic missile vehicles. This role focuses on leading the safe and reliable integration of the AUR, including Structural, electromechanical, thermal protection, and energetic assemblies. You will own end-to-end integration & test 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 vehicle level 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 2026-2027 Deliver the full manifest of integrated blackbeard vehicles Develop a plan to scale from development to low-rate initial production Support a rapid test flight cadence to validate vehicle capability Develop safe integration and testing processes for the vehicle that ensure operator safety Build a world-class integration and test engineering team that can independently support future facility development and production execution
Key Responsibilities:
Lead vehicle integration activities including mechanical mating, electrical interface verification, and safe separation testing.
Develop and execute comprehensive vehicle-level Integration & Test plans covering functional checkout, ordnance arming sequences, environmental qualification, and system verification.
Design and commission integration tooling, test fixtures, and automated test equipment for full missile assembly.
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.
Mentor integration & test engineers and lead cross-functional I&T teams during build and test campaigns.
Drive continuous improvement in integration processes, test automation, and digital thread implementation for faster iteration cycles.
Required Qualifications
Education:
Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, Systems Engineering, or related field.
Experience:
5+ years in integration and test for complex aerospace or defense systems.3+ years on flight hardware. Demonstrated leadership of vehicle-level integration and test campaigns, preferably on missile or hypersonic programs. Technical SkillsStrong experience with ordnance handling, safe-and-arm devices, and energetic materials integration. Proficiency in test automation (LabVIEW, Python, MATLAB), data acquisition systems, and telemetry. Hands-on with environmental testing and ordnance functional verification. Requirements management and configuration control. Familiarity with 3D CAD for integration planning.
Preferred Experience:- Direct experience on DoD missile, Orbital Launch, or other defense programs.
- Background in fast-paced development environments
- Soft SkillsProven ability to lead technical teams in high-stakes, safety-critical environments.
- Excellent communication and presentation skills for executive and customer briefings.
- Strong problem-solving under stringent safety and schedule constraints.
- Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.
- Other DutiesPlease 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.
- Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.
- Other DutiesPlease 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. 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.
