Senior Materials & Process Engineer, Materials Testing

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.

Senior Materials & Process Engineer, Materials Testing

Castelion is looking for an experienced Materials Characterization Engineer to act as the main technical resource for all materials testing at the company. In this role you will be responsible for all material coupon testing to support product development and qualification efforts.

The ideal candidate brings a strong background in materials science along with hands-on experience in mechanical testing, thermal analysis, and material characterization techniques. You should be comfortable running test hardware, interpreting test data, and working closely with cross-functional teams to provide clear, data-driven insights that support performance, reliability, and manufacturability.

Responsibilities

Own all materials coupon characterization test planning and execution for metals, composites, and bonded structures, in support of program qualification requirements and deadlines.

Lead development and maintenance of the material property allowables database.

Develop materials characterization lab including selection and commissioning of test hardware to improve capability, test lead-time and data quality.

Developed internal standardized test protocols based on relevant standards (ASTM, etc.).

Basic Qualifications

Bachelor's degree in materials engineering or a related field.

5+ years of experience working in materials testing, preferably within the aerospace industry.

Must be authorized to work in the U.S. and comply with ITAR eligibility requirements.

Preferred Skills and Experience

Strong hands-on experience with materials characterization and sample preparation techniques (mechanical testing, hardness testing, TGA, DSC, OM, SEM/EDS, FTIR, XRD).

Strong knowledge of material testing standards (ASTM, ISO, ASM, etc).

Excellent written and verbal communication skills.

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 able to work extended hours

Must be able to move and carry up to 25lbs

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.