Avionics Manufacturing Engineer, Electrical Integration

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 and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.

This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.

Avionics Manufacturing Engineer, Electrical Integration

Castelion is looking for an Avionics Manufacturing Engineer, Electrical Integration, reporting to the Lead Manufacturing Engineer of Avionics, to support the development and production of systems required for long-range hypersonic strike vehicles. This full-time position may be located at either our Allen, Texas, or Torrance, California facility.

As an Avionics Manufacturing Engineer focused on Electrical Integration, you will develop and improve the manufacturing processes used to integrate complex printed circuit board assemblies, electrical components, and interconnects into mechanical housings and higher-level avionics assemblies.

This role requires an understanding of electrical hardware, mechanical assembly, and manufacturing process control. You will write the work instructions and establish the process controls required to ensure avionics assemblies are built safely, correctly, and repeatably. You will also partner with other engineering teams to support the development of tooling, automation, inspection methods, and production testing.

The ideal candidate is comfortable working directly with flight hardware and can translate electrical, mechanical, thermal, and environmental requirements into practical manufacturing processes.

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

Basic Qualifications

• 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

Preferred Skills and Experience

• 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

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

Benefits And Perks

All full-time employees are granted meaningful long-term equity, sharing in the company's significant growth trajectory. We offer four (4) weeks of paid time off, ten (10) company-paid holidays, and comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage, along with dental and vision plans. We also provide paid parental leave to support growing families, a $100 monthly fitness stipend to promote health and performance, and onsite EV charging for convenience. In addition, employees enjoy perks like catered meals, company-covered food during high-demand periods, and a fully stocked kitchen to stay fueled throughout the day.

While this position does not currently require a U.S government-issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S. government–issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance.

Affirmative Action/EEO Statement

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.