R&D Technician - Hypersonics (Welding, Machining, Composites)

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. Were designing, building, and testing next generation long range strike weapons systems to give America and its Allies a definitive edge and deter future conflicts.

R&D Technician - Hypersonics (Welding, Machining, Composites)

Were looking for a hands-on R&D Technician to support prototype fabrication, assembly, and test of hypersonic systems. You'll work directly with engineers to translate designs into parts and assemblies - focusing on precision manual machining, TIG/MIG welding, and composite layup and repair - in a fast-paced R&D environment.

Key Responsibilities

• Fabricate, fit, and assemble prototype components to engineering drawings and verbal instructions.
• Perform manual machining operations (lathe, mill) for low-volume prototype parts and fixtures.
• Execute TIG and MIG welding on metallic components; perform tack, finish, and cleanup to assembly standards.
• Prepare, lay up, and cure composite parts; perform repairs and trimming as directed.
• Read and interpret engineering drawings, CAD prints, and inspection criteria.
• Support first-article builds, bench and lab tests, and iterative design changes.
• Perform basic inspection and dimensional checks; document work and non-conformances.
• Maintain clean, organized work area and follow shop safety and quality procedures.
• Collaborate with engineers to suggest manufacturability or assembly improvements.
• Assist in tooling fabrication, jigs, and fixtures as required.

Required Qualifications

• 3 years hands-on experience in a machine shop, fabrication shop, or aerospace manufacturing environment.
• Proficient in TIG and MIG welding on aerospace-grade metals (aluminum, stainless, common alloys).
• Practical experience with manual machining: lathes, mills, and basic tooling.
• Experience with composite materials: layup, trimming, sanding, and small repairs.
• Able to read and interpret engineering drawings and follow detailed instructions.
• Strong attention to detail, good manual dexterity, and mechanical troubleshooting skills.
• Comfortable working in a team environment and communicating with engineers.
• Willingness to work in a safety-conscious, controlled environment (PPE, cleanroom practices as required).

Preferred Qualifications / Nice-to-Have

• Certifications: Welding (AWS), machining (NIMS), or composite technician training.
• Prior experience with prototype or aerospace components.
• Familiarity with basic inspection tools (calipers, micrometers, height gauges).
• Experience with basic hand & power tools, band saw, grinders, deburring tools.
• Experience working on classified/secure programs or prior cleared contractor experience.

Physical & Other Requirements

• Ability to lift up to ~50 lbs occasionally and stand for extended periods.
• Ability to work with chemical resins, solvents, and adhere to PPE protocols.
• Shift flexibility as project needs dictate.
• Clearance: May require U.S. citizenship and the ability to obtain/maintain a security clearance.

Why Join Us

Work at the cutting edge of hypersonics development in a collaborative R&D environment where your workmanship directly impacts prototype performance and test outcomes.

Leadership Qualities

• Bias to Action and Creative Problem Solving. Desire and experience questioning assumptions in ways that lead to break through ideas that are ultimately implemented. Successfully bring in applicable processes/concepts/materials from other industries to achieve efficiency gains. Have the 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 blockers. Trusted in previous roles to be voice of company with regulators, suppliers, gate keepers and customers. Capable of tactfully managing relationships with stakeholders to achieve company-desired outcomes without compromising relationships. Emails, IMs and verbal interactions are logical, drive clarity, and detailed enough to eliminate ambiguity.

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.

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