Senior Mechanical Design Engineer (ACS Systems)

Responsibilities

• Design and develop ACS hardware, including propellant tanks, valves, thrusters, and associated fluid system assemblies
• Lead the architecture and detailed design of pressure vessels, fluid lines, mounts, and integrated ACS packaging within the vehicle
• Perform structural, thermal, and fluid analyses to ensure performance and reliability under extreme pressure, temperature, and dynamic environments
• Work closely with propulsion, GNC, avionics, and structures teams to ensure seamless integration of ACS systems with vehicle architecture
• Conduct tolerance analysis, sealing strategy development, and leak-tightness assessments for high-pressure systems
• Support prototyping, assembly, and hardware bring-up, including troubleshooting and root cause analysis of system performance issues
• Define and execute qualification and environmental test plans, including pressure, vibration, thermal, and shock testing
• Optimize designs for mass, reliability, manufacturability, and ease of integration
• Mentor junior engineers and contribute to best practices in mechanical and fluid system design
• Partner closely with program leadership to make technical trades aligned with mission success
• Basic Qualifications
• Bachelor's, Master's, or PhD in Mechanical Engineering or related field
• 5+ years of experience in mechanical design for aerospace or high-performance fluid/propulsion systems
• Strong background in pressure vessel design, fluid systems, and high-pressure component integration
• Experience designing tanks, valves, thrusters, or similar propulsion or ACS hardware
• Familiarity with sealing methods, leak detection, and cleanliness requirements for high-reliability fluid systems
• Proficiency in CAD and analysis tools (e.g., NX, SolidWorks, ANSYS, or equivalent)
• Experience with structural analysis, thermal analysis, and tolerance stack-up analysis
• Familiarity with high-temperature materials and operation in extreme environments
• Experience with hardware build, test, and troubleshooting in a lab or flight hardware environment
• Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high flight cadence environment
• 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.