Lead Integration & Test Engineer

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

• • 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 planning
• • U.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

Long-term stock incentives for all employees. Comprehensive medical, vision, and dental insurance, plus four weeks of paid time off per year.

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.