Senior Materials & Process Engineer

Senior Materials & Process Engineer

Castelion is bringing a new approach to defense development and production: short, iterative design cycles, rapid testing, and modern commercial manufacturing strategies for 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.

Castelion is seeking a Senior Materials & Process Engineer to develop and validate epoxy bonding processes for our long‑range, precision strike hypersonic missiles. This role reports directly to the Head of Manufacturing and works closely with Materials and Design Engineering teams to test and integrate epoxy bonding processes. A strong understanding of epoxy adhesives and their interactions with other materials is essential, as the engineer will serve as the subject‑matter expert for the entire organization.

• Evaluate and select appropriate materials based on design requirements, performance specifications, and cost‑effectiveness.
• Develop, improve, and optimize manufacturing processes, ensuring efficient and cost‑effective production while maintaining product quality.
• Design test plans and conduct material testing (mechanical, thermal, etc.) to evaluate suitability for specific applications.
• Investigate material or process‑related failures and develop corrective actions to prevent recurrence.
• Prepare technical reports, material specifications, and process documentation to support product development, quality assurance, and regulatory compliance.
• Stay updated on new materials, emerging technologies, and industry best practices to improve materials and processes and enhance product performance.
• Support the development of internal engineering and quality processes to standardize and accelerate material evaluation, implementation, and qualification.
• Lead and coordinate internal and external M&P efforts, including the development of material and process specifications, supplier qualifications, part qualifications, mechanical testing, and customer‑facing updates.

• Education: Bachelor's degree in Materials Science, Mechanical Engineering, Chemical Engineering, or related field. A Master's degree is a plus.
• Experience: 5+ years of experience in materials and processes engineering, preferably within aerospace/automotive.
• Knowledge: Strong knowledge of materials properties, testing methods, and manufacturing processes (e.g., casting, welding, additive manufacturing, etc.).
• Skills:
• Proficient in materials characterization techniques (e.g. metallographic mounting, OM/SEM microscopy, mechanical testing).
• Strong problem‑solving skills and attention to detail.
• Excellent communication skills, both written and verbal.
• Ability to work in a fast‑paced, multidisciplinary team environment.

• Knowledge of industry‑specific regulations, certifications, and standards (e.g., ASTM, ISO, MIL‑SPEC).
• Experience in failure analysis or root cause investigation.
• Experience with adhesive bonding processes.
• Experience with interfacial strength characterization methods (e.g. lap shear, tensile loading peel tests).
• Familiarity with polymer specific characterization techniques (DSC, TGA, rheometry, FTIR).

• Must be willing to work extended hours and/or weekends as needed.
• Must be able to travel up to 10% of the time.

• 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/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…