Avionics Manufacturing Engineer, Electrical Integration

About the role

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.

Responsibilities

• Develop and improve manufacturing processes for integrating PCBAs and electrical components into mechanical housings and higher-level avionics assemblies
• Write clear work instructions, visual aids, assembly procedures, and inspection criteria for avionics hardware
• Establish process controls for the installation of PCBAs, thermal interface materials, gaskets, fasteners, connectors, grounding features, and electrical interconnects
• Define and validate critical assembly parameters, including material placement, surface preparation, fastener torque, tightening sequence, compression, alignment, and cleanliness
• Partner with Design, Test, and Manufacturing Engineering to support the development of tooling, fixtures, automation, inspection methods, and production test equipment
• Review electrical schematics, PCBA drawings, mechanical drawings, bills of material, and assembly documentation to determine manufacturing requirements
• Provide manufacturability feedback related to assembly sequence, component access, connector routing, grounding, thermal management, tolerance stack-up, tooling access, and test access
• Troubleshoot electrical and electro-mechanical assembly issues and support root-cause investigations and corrective actions
• Support technicians during development and production builds and provide training on new or improved manufacturing processes
• Support the transition of avionics hardware from development builds into controlled, repeatable production
• Partner with Design Engineering, Test Engineering, Quality, Planning, Supply Chain, and Production to resolve manufacturing issues
• Improve first-pass yield, assembly time, workmanship, production flow, and process repeatability

Requirements

• Bachelor's degree in electrical, mechanical, manufacturing, aerospace engineering, or a related technical field
• 3+ years of experience in avionics, electronics, electrical integration, electro-mechanical assembly, or high-reliability manufacturing
• Hands-on experience integrating PCBAs or electrical components into mechanical assemblies
• Experience developing manufacturing processes, work instructions, inspection criteria, or process controls
• Ability to read electrical schematics, PCBA drawings, mechanical drawings, and manufacturing documentation
• Strong hands-on troubleshooting, communication, and technical problem-solving skills
• Must be willing to work extended hours and/or weekends as needed
• Must be able to travel up to 25% of the time

Skills

• Experience manufacturing or integrating flight avionics, defense electronics, automotive electronics, or other high-reliability hardware
• Experience with thermal interface materials, gap fillers, thermal pads, adhesives, gaskets, environmental seals, fasteners, and grounding features
• Experience supporting the development of manufacturing tooling, fixtures, automation, or production test equipment
• Experience with process validation and manufacturing acceptance criteria
• Familiarity with GD&T, tolerance stack-ups, mechanical fits, fastener torque, and electro[1]mechanical assembly processes
• Experience with electrical continuity, grounding, hipot, insulation resistance, or functional testing
• Working knowledge of IPC-A-610, IPC/WHMA-A-620, or similar workmanship standards
• Experience supporting both development and production hardware in a fast-paced aerospace or defense environment

Benefits

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.