Lead Integration & Test Engineer

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, * 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.

Integration Testing, Integration Testing, Manufacturing, Test Strategy, Propulsion, Electromechanics, Military/DoD Standards, Campaigns, Quality Assurance, Testing, * Bachelor’’s or Master’’s degree in Aerospace Engineering, Mechanical Engineering, Systems Engineering, or related field., * 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 Skills

• Strong 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
• Prior flight test support at ranges

Soft Skills

• Proven 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.

Why Castelion, Why Now

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., This field is for validation purposes and should be left unchanged.