Automation & Controls Engineer

Responsibilities

• Design and program full control systems (PLC, HMI, SCADA) for SRM manufacturing equipment including vertical mixers, casting stations, robotic winding cells, cure ovens, and automated handling systems.
• Develop motion control, servo, and robotics architectures for precision propellant loading, composite case fabrication, and component assembly.
• Implement safety instrumented systems (SIS), functional safety, and hazardous area controls compliant with requirements for energetic materials.
• Integrate machine vision, sensors, data acquisition, and real-time monitoring for process parameters (viscosity, temperature, pressure, void detection) and statistical process control (SPC).
• Lead equipment commissioning, factory acceptance testing (FAT), site acceptance testing (SAT), debugging, and production qualification.
• Build data historian, MES interfaces, and analytics platforms for traceability, yield optimization, and predictive maintenance.
• Collaborate with teams to translate manufacturing requirements into robust, maintainable automation solutions.
• Perform failure mode analysis, root-cause troubleshooting, and continuous improvement to achieve aggressive cycle-time and quality targets.
• Support technology insertion of Industry 4.0 tools (digital twins, AI-driven monitoring) for future SRM production lines.
• Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.
• 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.
• Additional Eligibility Requirements
• This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.
• Affirmative Action/EEO Statement
• Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law.
• Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact [email protected]. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law.
• Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation.
• EAR/ITAR Requirements
• This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.