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BlueYard Capital

Senior Manufacturing Engineer - High Temperature Composites



El Segundo, CA, USA
Posted on Friday, February 23, 2024

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’re 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 Manufacturing Engineer - High Temperature Composites

Castelion is seeking an expert in composites manufacturing to help define and scale our in-house composites manufacturing processes from raw material to flight parts. This will include scaling our current ceramic matrix composite (CMC) production line and supporting day to day production of all composite vehicle components including nozzles, aeroshells, fins, etc. This role will report directly to Castelion’s Head of Manufacturing and work closely with the engineering leadership team to identify and eliminate roadblocks to achieving long term company goals. As an early hire on the manufacturing team, this role will be highly influential in defining manufacturing and production strategy and culture at Castelion.


  • Identify, plan, and execute capital equipment, machine, and facility/layout definition to meet business needs
  • Develop and refine process documentation including build instructions, test and validation procedures, health and safety standards, and mBOMs
  • Create, maintain, and communicate detailed production plans and schedules
  • Work closely with supply chain to develop new and existing suppliers as needed
  • Design, develop and implement production tooling and equipment
  • Participate in design reviews to drive design for manufacturing (DFM)
  • Oversee introduction and implementation of new products and manufacturing capabilities
  • Analyze and resolve manufacturing issues and non-conformances
  • Develop, mentor, and train peers and colleagues

Basic Qualifications

  • Bachelor’s degree in mechanical, aerospace, or manufacturing engineering, or other technical degree.
  • 8+ years of composite manufacturing experience
  • Experience with operations/product line management
  • Demonstrated direct or indirect leadership
  • Proficiency in CAD/CAM software (NX preferred)
  • Experience in selection, procurement, and implementation/validation of manufacturing equipment

Preferred Qualifications

  • Experience in filament winding, automated fiber placement and/or automated tape laying
  • Experience with Non-Destructive Testing/Inspection of composite components
  • Experience in qualification and acceptance testing of composite structural components
  • Working experience with capacity modeling, process mapping, Lean/Six Sigma and value stream mapping
  • Experience with Ceramic Matrix Composites
  • Experience in transitioning development processes to rate production

Additional Requirements

  • Must be willing to work extended hours and/or weekends as needed.
  • Must be able to travel up to 30%

All employees are granted long-term stock incentives as part of their employment as Castelion. All employees receive access to comprehensive medial, vision, and dental insurance, and the company offers three weeks of paid time off per year.

ITAR Requirements:

  • To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee 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 governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.