Senior Manufacturing Engineer – Sheet Metal Forming & Welding
Castelion · Torrance, CA · 1 mo ago
On-siteManufacturingFull-time
We need to output HTML fragment with sections: About the role? Actually we have "Why Castelion, Why Now" intro paragraph, then "Position Overview", then "Key Responsibilities", then "Required Qualifications", then "Preferred Experience", then "Soft Skills", then "Castelion offers a generous benefits package..." but we only include sections if they have real specific content. Benefits: they say "generous benefits package" but no specifics, so we should NOT include Benefits section because no specific details. Pay/Schedule: not present, so omit. Also we should not repeat job title as heading. We need to use for section headings. Use
for section headings. Use - for any list of duties/requirements/benefits. Use
for prose.
We need to preserve all substantive info, remove boilerplate: cookie/navigation/legal/EEO/equal-opportunity/scam-warning, duplicated lines, application instructions. Also remove "Other Duties", "Additional Eligibility Requirements", "Affirmative Action/EEO Statement", "EAR/ITAR Requirements"? Those are legal/EEO etc. Should be removed. Also remove "Please refer to the bottom of our Careers page for more details." That's boilerplate.
We need to keep the intro "Why Castelion, Why Now" maybe as a section? The instruction: use
for section headings (e.g. About the role, Responsibilities, Requirements, Qualifications, Skills, Benefits, Pay, Schedule). It says we can use those example headings, but we can also use other headings? Probably we should map content to those headings. The posting includes: "Why Castelion, Why Now" (intro), "Position Overview", "Key Responsibilities", "Required Qualifications", "Preferred Experience", "Soft Skills". Also maybe "Castelion offers a generous benefits package." but we omit benefits due to lack specifics.
We need to decide headings: Could use "About the role" for Position Overview and intro? Or we could have separate sections: "About the role" (combining Why Castelion, Why Now and Position Overview). "Responsibilities" for Key Responsibilities. "Requirements" for Required Qualifications. "Skills" for Preferred Experience and Soft Skills combined? Or separate "Preferred Experience" and "Soft Skills"? The instruction says prefer a few substantive sections over many thin ones. So we could combine Preferred Experience and Soft Skills into a "Skills" section. Also we could have "Qualifications" for Required Qualifications.
Thus sections: About the role (h3), Responsibilities (h3), Requirements (h3), Skills (h3). Ensure we only include sections with real content.
Now we need to format content.
About the role: combine the intro paragraph "Why Castelion, Why Now..." and the Position Overview paragraph. Let's extract:
"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."
Then Position Overview: "We are seeking a Senior Manufacturing Engineer to own sheet metal forming and welding processes for Castelion’s solid rocket motor and hypersonic vehicle hardware. This role is responsible for developing, qualifying, and scaling fabrication of formed and welded metallic structures. You will define forming methods, weld processes, fixtures, inspection, and production flow while partnering with Design, Quality, Tooling & Automation, and Operations. The objective is repeatable, flight-quality metallic hardware from development builds through high-rate production."
Combine into prose paragraphs maybe separate
tags.
Responsibilities: list of duties from "Key Responsibilities". Need to convert each bullet into
- . The responsibilities are sentences separated by periods. We'll create list items.
Let's extract bullet points:
- Own manufacturing processes for sheet metal forming and welding, including cutting, bending, rolling, hydroforming or equivalent forming methods, fit-up, welding, post-weld processing, and final inspection.
- Develop and qualify weld procedures, forming processes, fixtures, and work instructions that meet dimensional, structural, and quality requirements.
- Execute DFM/DFA, PFMEA, control plans, and statistical process control (SPC) to improve first-pass yield, cycle time, and cost.
- Define inspection and NDE strategies for formed and welded hardware (dimensional inspection, visual weld inspection, and approved NDE methods).
- Partner with Tooling, Automation & Controls on forming dies, weld fixtures, positioners, and semi-automated or robotic welding cells.
- Support new product introduction and design changes with producibility input on material selection, bend radii, weld joint design, tolerances, and assembly sequence.
- Lead root-cause analysis and corrective actions for forming defects, weld defects, distortion, fit-up issues, and dimensional escapes.
- Author and maintain travelers, WPS/PQR support documentation as applicable, and quality records compliant with AS9100 and customer requirements.
- Collaborate with suppliers on sheet stock, formed details, and welded subassemblies; drive incoming quality and process capability.
- Support equipment qualification and production ramp in Torrance, CA and the Project Ranger campus in New Mexico.
We'll put each as
- .
Requirements: Required Qualifications section includes Education, Experience, Technical Skills. We'll format as list maybe separate subheadings? But we only have
- for list. Could embed paragraphs. Probably better to have
for prose and
- for lists like experience bullet points.
We have:
Education: Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
Experience: 6–10+ years of manufacturing engineering experience in aerospace, defense, or high-reliability metallic fabrication. 3+ years of hands-on ownership of sheet metal forming and welding processes on flight or mission-critical hardware. Demonstrated success qualifying fabrication processes and transitioning them from development to production.
Technical Skills: Strong practical knowledge of sheet metal forming (brake, roll, stretch, hydroform, or equivalent) and fusion welding processes used in aerospace production. Proficiency in CAD (SolidWorks or NX), GD&T, tolerance stack-up, and fixture concepting. Working knowledge of weld procedure development, distortion control, fit-up, and post-weld heat treatment or finishing as applicable. Experience with PFMEA, SPC, root-cause methods (8D, fishbone), and process qualification. Familiarity with metrology and NDE of formed and welded structures. Ability to write clear work instructions and support shop-floor execution.
We could make a list for each bullet under Experience and Technical Skills.
Skills section: Preferred Experience + Soft Skills.
Preferred Experience bullet points:
- Direct manufacturing experience on missile, rocket-motor, or aerospace structural metallic hardware.
- Background in fast-paced defense or space production environments.
- Experience with robotic or automated welding and forming cells.
- Prior work on stainless, high-strength steels, nickel alloys, aluminum, or other aerospace alloys used in propulsion or vehicle structures.
- Familiarity with AS9100, ITAR programs, and manufacturing in energetic-materials facilities.
- Track record reducing scrap, rework, distortion, or cycle time on welded or formed flight hardware.
Soft Skills bullet points:
- Hands-on, detail-oriented, and effective at enforcing process discipline on the shop floor.
- Strong collaboration with Design, Quality, Tooling, and Operations teams.
- Clear technical communication and documentation skills.
- Data-driven problem solver under schedule pressure.
- Safety-first mindset when working in facilities that handle energetic materials.
We'll combine into a Skills section with list items.
Now produce HTML fragment:
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.
We are seeking a Senior Manufacturing Engineer to own sheet metal forming and welding processes for Castelion’s solid rocket motor and hypersonic vehicle hardware. This role is responsible for developing, qualifying, and scaling fabrication of formed and welded metallic structures. You will define forming methods, weld processes, fixtures, inspection, and production flow while partnering with Design, Quality, Tooling & Automation, and Operations. The objective is repeatable, flight-quality metallic hardware from development builds through high-rate production.
Responsibilities
- Own manufacturing processes for sheet metal forming and welding, including cutting, bending, rolling, hydroforming or equivalent forming methods, fit-up, welding, post-weld processing, and final inspection.
- Develop and qualify weld procedures, forming processes, fixtures, and work instructions that meet dimensional, structural, and quality requirements.
- Execute DFM/DFA, PFMEA, control plans, and statistical process control (SPC) to improve first-pass yield, cycle time, and cost.
- Define inspection and NDE strategies for formed and welded hardware (dimensional inspection, visual weld inspection, and approved NDE methods).
- Partner with Tooling, Automation & Controls on forming dies, weld fixtures, positioners, and semi-automated or robotic welding cells.
- Support new product introduction and design changes with producibility input on material selection, bend radii, weld joint design, tolerances, and assembly sequence.
- Lead root-cause analysis and corrective actions for forming defects, weld defects, distortion, fit-up issues, and dimensional escapes.
- Author and maintain travelers, WPS/PQR support documentation as applicable, and quality records compliant with AS9100 and customer requirements.
- Collaborate with suppliers on sheet stock, formed details, and welded subassemblies; drive incoming quality and process capability.
- Support equipment qualification and production ramp in Torrance, CA and the Project Ranger campus in New Mexico.
Requirements
Education: Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
Experience:
- 6–10+ years of manufacturing engineering experience in aerospace, defense, or high-reliability metallic fabrication.
- 3+ years of hands-on ownership of sheet metal forming and welding processes on flight or mission-critical hardware.
- Demonstrated success qualifying fabrication processes and transitioning them from development to production.
Technical Skills:
- Strong practical knowledge of sheet metal forming (brake, roll, stretch, hydroform, or equivalent) and fusion welding processes used in aerospace production.
- Proficiency in CAD (SolidWorks or NX), GD&T, tolerance stack-up, and fixture concepting.
- Working knowledge of weld procedure development, distortion control, fit-up, and post-weld heat treatment or finishing as applicable.
- Experience with PFMEA, SPC, root-cause methods (8D, fishbone), and process qualification.
- Familiarity with metrology and NDE of formed and welded structures.
- Ability to write clear work instructions and support shop-floor execution.
Skills
- Direct manufacturing experience on missile, rocket-motor, or aerospace structural metallic hardware.
- Background in fast-paced defense or space production environments.
- Experience with robotic or automated welding and forming cells.
- Prior work on stainless, high-strength steels, nickel alloys, aluminum
for prose. We need to preserve all substantive info, remove boilerplate: cookie/navigation/legal/EEO/equal-opportunity/scam-warning, duplicated lines, application instructions. Also remove "Other Duties", "Additional Eligibility Requirements", "Affirmative Action/EEO Statement", "EAR/ITAR Requirements"? Those are legal/EEO etc. Should be removed. Also remove "Please refer to the bottom of our Careers page for more details." That's boilerplate. We need to keep the intro "Why Castelion, Why Now" maybe as a section? The instruction: use
for section headings (e.g. About the role, Responsibilities, Requirements, Qualifications, Skills, Benefits, Pay, Schedule). It says we can use those example headings, but we can also use other headings? Probably we should map content to those headings. The posting includes: "Why Castelion, Why Now" (intro), "Position Overview", "Key Responsibilities", "Required Qualifications", "Preferred Experience", "Soft Skills". Also maybe "Castelion offers a generous benefits package." but we omit benefits due to lack specifics. We need to decide headings: Could use "About the role" for Position Overview and intro? Or we could have separate sections: "About the role" (combining Why Castelion, Why Now and Position Overview). "Responsibilities" for Key Responsibilities. "Requirements" for Required Qualifications. "Skills" for Preferred Experience and Soft Skills combined? Or separate "Preferred Experience" and "Soft Skills"? The instruction says prefer a few substantive sections over many thin ones. So we could combine Preferred Experience and Soft Skills into a "Skills" section. Also we could have "Qualifications" for Required Qualifications. Thus sections: About the role (h3), Responsibilities (h3), Requirements (h3), Skills (h3). Ensure we only include sections with real content. Now we need to format content. About the role: combine the intro paragraph "Why Castelion, Why Now..." and the Position Overview paragraph. Let's extract: "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." Then Position Overview: "We are seeking a Senior Manufacturing Engineer to own sheet metal forming and welding processes for Castelion’s solid rocket motor and hypersonic vehicle hardware. This role is responsible for developing, qualifying, and scaling fabrication of formed and welded metallic structures. You will define forming methods, weld processes, fixtures, inspection, and production flow while partnering with Design, Quality, Tooling & Automation, and Operations. The objective is repeatable, flight-quality metallic hardware from development builds through high-rate production." Combine into prose paragraphs maybe separate
tags. Responsibilities: list of duties from "Key Responsibilities". Need to convert each bullet into
- for list. Could embed paragraphs. Probably better to have
for prose and
- for lists like experience bullet points.
We have:
Education: Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
Experience: 6–10+ years of manufacturing engineering experience in aerospace, defense, or high-reliability metallic fabrication. 3+ years of hands-on ownership of sheet metal forming and welding processes on flight or mission-critical hardware. Demonstrated success qualifying fabrication processes and transitioning them from development to production.
Technical Skills: Strong practical knowledge of sheet metal forming (brake, roll, stretch, hydroform, or equivalent) and fusion welding processes used in aerospace production. Proficiency in CAD (SolidWorks or NX), GD&T, tolerance stack-up, and fixture concepting. Working knowledge of weld procedure development, distortion control, fit-up, and post-weld heat treatment or finishing as applicable. Experience with PFMEA, SPC, root-cause methods (8D, fishbone), and process qualification. Familiarity with metrology and NDE of formed and welded structures. Ability to write clear work instructions and support shop-floor execution.
We could make a list for each bullet under Experience and Technical Skills.
Skills section: Preferred Experience + Soft Skills.
Preferred Experience bullet points:
- Direct manufacturing experience on missile, rocket-motor, or aerospace structural metallic hardware.
- Background in fast-paced defense or space production environments.
- Experience with robotic or automated welding and forming cells.
- Prior work on stainless, high-strength steels, nickel alloys, aluminum, or other aerospace alloys used in propulsion or vehicle structures.
- Familiarity with AS9100, ITAR programs, and manufacturing in energetic-materials facilities.
- Track record reducing scrap, rework, distortion, or cycle time on welded or formed flight hardware.
Soft Skills bullet points:
- Hands-on, detail-oriented, and effective at enforcing process discipline on the shop floor.
- Strong collaboration with Design, Quality, Tooling, and Operations teams.
- Clear technical communication and documentation skills.
- Data-driven problem solver under schedule pressure.
- Safety-first mindset when working in facilities that handle energetic materials.
We'll combine into a Skills section with list items.
Now produce HTML fragment:
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.
We are seeking a Senior Manufacturing Engineer to own sheet metal forming and welding processes for Castelion’s solid rocket motor and hypersonic vehicle hardware. This role is responsible for developing, qualifying, and scaling fabrication of formed and welded metallic structures. You will define forming methods, weld processes, fixtures, inspection, and production flow while partnering with Design, Quality, Tooling & Automation, and Operations. The objective is repeatable, flight-quality metallic hardware from development builds through high-rate production.
Responsibilities
- Own manufacturing processes for sheet metal forming and welding, including cutting, bending, rolling, hydroforming or equivalent forming methods, fit-up, welding, post-weld processing, and final inspection.
- Develop and qualify weld procedures, forming processes, fixtures, and work instructions that meet dimensional, structural, and quality requirements.
- Execute DFM/DFA, PFMEA, control plans, and statistical process control (SPC) to improve first-pass yield, cycle time, and cost.
- Define inspection and NDE strategies for formed and welded hardware (dimensional inspection, visual weld inspection, and approved NDE methods).
- Partner with Tooling, Automation & Controls on forming dies, weld fixtures, positioners, and semi-automated or robotic welding cells.
- Support new product introduction and design changes with producibility input on material selection, bend radii, weld joint design, tolerances, and assembly sequence.
- Lead root-cause analysis and corrective actions for forming defects, weld defects, distortion, fit-up issues, and dimensional escapes.
- Author and maintain travelers, WPS/PQR support documentation as applicable, and quality records compliant with AS9100 and customer requirements.
- Collaborate with suppliers on sheet stock, formed details, and welded subassemblies; drive incoming quality and process capability.
- Support equipment qualification and production ramp in Torrance, CA and the Project Ranger campus in New Mexico.
Requirements
Education: Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
Experience:
- 6–10+ years of manufacturing engineering experience in aerospace, defense, or high-reliability metallic fabrication.
- 3+ years of hands-on ownership of sheet metal forming and welding processes on flight or mission-critical hardware.
- Demonstrated success qualifying fabrication processes and transitioning them from development to production.
Technical Skills:
- Strong practical knowledge of sheet metal forming (brake, roll, stretch, hydroform, or equivalent) and fusion welding processes used in aerospace production.
- Proficiency in CAD (SolidWorks or NX), GD&T, tolerance stack-up, and fixture concepting.
- Working knowledge of weld procedure development, distortion control, fit-up, and post-weld heat treatment or finishing as applicable.
- Experience with PFMEA, SPC, root-cause methods (8D, fishbone), and process qualification.
- Familiarity with metrology and NDE of formed and welded structures.
- Ability to write clear work instructions and support shop-floor execution.
Skills
- Direct manufacturing experience on missile, rocket-motor, or aerospace structural metallic hardware.
- Background in fast-paced defense or space production environments.
- Experience with robotic or automated welding and forming cells.
- Prior work on stainless, high-strength steels, nickel alloys, aluminum
- for lists like experience bullet points.
We have:
Education: Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Welding Engineering, Materials Science, or related field.
Experience: 6–10+ years of manufacturing engineering experience in aerospace, defense, or high-reliability metallic fabrication. 3+ years of hands-on ownership of sheet metal forming and welding processes on flight or mission-critical hardware. Demonstrated success qualifying fabrication processes and transitioning them from development to production.
Technical Skills: Strong practical knowledge of sheet metal forming (brake, roll, stretch, hydroform, or equivalent) and fusion welding processes used in aerospace production. Proficiency in CAD (SolidWorks or NX), GD&T, tolerance stack-up, and fixture concepting. Working knowledge of weld procedure development, distortion control, fit-up, and post-weld heat treatment or finishing as applicable. Experience with PFMEA, SPC, root-cause methods (8D, fishbone), and process qualification. Familiarity with metrology and NDE of formed and welded structures. Ability to write clear work instructions and support shop-floor execution.
We could make a list for each bullet under Experience and Technical Skills.
Skills section: Preferred Experience + Soft Skills.
Preferred Experience bullet points:
- Direct manufacturing experience on missile, rocket-motor, or aerospace structural metallic hardware.
- Background in fast-paced defense or space production environments.
- Experience with robotic or automated welding and forming cells.
- Prior work on stainless, high-strength steels, nickel alloys, aluminum, or other aerospace alloys used in propulsion or vehicle structures.
- Familiarity with AS9100, ITAR programs, and manufacturing in energetic-materials facilities.
- Track record reducing scrap, rework, distortion, or cycle time on welded or formed flight hardware.
Soft Skills bullet points:
- Hands-on, detail-oriented, and effective at enforcing process discipline on the shop floor.
- Strong collaboration with Design, Quality, Tooling, and Operations teams.
- Clear technical communication and documentation skills.
- Data-driven problem solver under schedule pressure.
- Safety-first mindset when working in facilities that handle energetic materials.
We'll combine into a Skills section with list items.
Now produce HTML fragment: