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

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. 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.

About the role

We’re 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.

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.

Requirements

• 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

• 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.
• May require U.S. citizenship and the ability to obtain/maintain a security clearance.

Benefits

• All employees are granted long-term stock incentives as part of their employment at Castelion.
• Comprehensive medical, vision, and dental insurance.
• Four weeks of paid time off per year.

Leadership Qualities

• 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. Have the ability to personally resolve minor issues in development without requiring significant support.
• High Commitment, High Initiative: 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, gatekeepers, 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.

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.