Principal Build Reliability Engineer

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 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.

Principal Build Reliability Engineer

Castelion is seeking a Build Reliability Engineer to ensure the reliability of flight components and assemblies. This individual will evaluate product and process output data to drive improvements in manufacturing quality and actively represent quality objectives in design and development teams.

Responsibilities

This individual will evaluate product and process output data to drive improvements in manufacturing quality, and actively represent quality objectives in design and development teams

Design for Manufacture

Participating in Preliminary Design Review (PDR) / Critical Design Review (CDR) to ensure design for quality (DFQ), design for manufacturability (DFM), risk quantification and mitigation, and that appropriate test validation methods and inspection techniques, including nondestructive evaluation methods, have been considered

Hands-on development of design for manufacturability through ensuring identification of key characteristics, prototype testing for manufacturability, First Article and Detailed Inspection planning, evaluation of previous non-conformances and lessons learned, and other manufacturing and quality tools as required

Inspection and Test Process Development

Leads inspection planning for new products through identification of features and gages, and integration with planned operations

Designs or procures new measurement methods as required and integrates with existing processes
Validates new and existing measurement and tests methods using process capability and measurement systems analysis (MSA) statistical tools
Propose solutions to remove the need to verify product conformance through measurement, e.g. poka-yoke
First Build Reviews and Walk downs
Co-ordinates, schedules and facilitates objective First Build Reviews to ensure transparency of design intent, design requirements, design and manufacturing risks, and manufacturability of design
Develop and maintains engineering walk down criteria for major product milestones to provide clear guidance to Production on engineering intent and acceptance criteria
Identifies photo closeout requirements for complete as-built documentation
Evaluates and analyzes production quality landscape
Uses data to make landscape transparent and drive project prioritization
Responsible for ensuring that issues related to product reliability are primary focus
Drives achievement of quality targets through a review hierarchy with appropriate levels of management
Ensure controls in place to prevent recurrence
Root Cause and Corrective Action Investigations
Leads, facilitates, and participates in root cause investigations in their respective area
Deep dives using appropriate quality or analysis tools as required
Ensures documentation of cause and corrective action is captured appropriately
Ensures appropriate actions to prevent recurrence
Containment
Leads activity to support containment of all suspect products
Provides guidance to quality inspectors, techs, and shop supervisors to assist in quarantining of all suspected products
Communicate status of evaluation and disposition to production leadership on a regular basis
Issue Ticket Review/Audit/Closure
Supports review of all issue tickets in respective areas
Ensures rationale and documentation of design deviation is captured
Leads and coordinates the management of non-conforming hardware
Review of Engineering Masters (EM), Work Order (WO) instructions and drawings
Reviews and approves Engineering Orders (EO's), Engineering Masters (EM's), Work Orders (WO's), specifications, and product introduction and documentation for completeness, accuracy, regulatory compliance, and quality objectives
Validates that drawing captures all requirements needed to build and inspect hardware
Develop Inspection plans and modifies as required for process or design changes
Ensures inspection/test criteria are objective with clear pass/fail criteria
Production Process Audit/Improvement
Assesses new processes for safety and product risks
Ensures adherence to QMS policy and procedures within their work center
Develop criteria and builds audits to identify process weaknesses

Basic Qualifications

Bachelor's or advanced degree in aerospace engineering, manufacturing engineering, materials engineering, mechanical engineering or physics.

Minimum 5+ years in a quality, manufacturing, or design engineering role

Preferred Skills and Experience

Experience supporting production of complex electro-mechanical, mechanical, or composites systems in high volume work centers and/or during production ramp-up.

Knowledge of quality tools such as Lean principles, Six Sigma, Root Cause Analysis and Corrective Action, Advanced Product Quality Planning (APQP), Metrology, Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and various problem-solving approaches.

Dedicated to adopting a Lean approach to quality without compromising safety or reliability.

Benefits And Perks

Employee Equity: Meaningful equity for all full-time employees - share value has increased 150x in three years

Personal Time Off: Four (4) weeks of paid time off to unplug, reset, and come back sharp—velocity matters, burnout doesn't

Company Paid Holidays: Ten (10) company paid holidays

Medical: We offer plans at 100% employee covered and 80% of dependent coverage

Dental & Vision: We cover 90% employees and 80% for dependents to ensure you and your family have access to quality preventive and ongoing care

FSA/HSA: To support long-term health and financial resilience, we offer FSA and HSA options that allow employees to set aside pre-tax dollars for eligible medical and dependent care expenses

Retirement: 401k plan offered to support long term financial growth along side high-impact, high-velocity work

Paid Parental Leave: We support growing families with meaningful time to bond and recover. Birthing parents are eligible for up to 10 weeks of paid leave, while non-birthing parents may take up to 4 weeks of paid leave. This time can be used for pre-natal care, pregnancy, childbirth, and related medical needs—ensuring every parent has the support they need during this important life moment.8-weeks of paid parental leave for all parents. Additional paid pregnancy leave for CA employees

Meals & Catering: Frequently catered lunches and team meals, plus company-covered meals when extra time or effort is required

Snacks & Beverages: Fully stocked kitchen with unlimited snacks and drinks to keep you fueled throughout the day

Performance & Fitness: $100 monthly fitness stipend to support peak performance and health, both inside and outside of work

EV Charging: Onsite electric vehicle charging available for employees

Physical Demands

Must be willing to work extended hours and/or weekends as needed

Must be able to travel up to 30%

Must be able to lift more than 50lbs

ITAR Requirements

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.

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. Failure to obtain or maintain any required clearance or authorization may result in reassignment, leave, or separation from employment, consistent with business needs and applicable law.

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.

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.