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Castelion · 3 days ago

Manufacturing Engineer - Case Lining & Paint

Torrance, CA

Full-time

Onsite

Senior Level

5+ years exp

Castelion is a company focused on innovative defense development and production, aiming to enhance America's military capabilities. They are seeking a Manufacturing Engineer to manage the case lining, insulation, and protective coating processes for solid rocket motor programs, ensuring the development and scaling of efficient manufacturing practices.

AerospaceGovernmentManufacturingMilitaryNational Security

No H1B

U.S. Citizen Only

Hiring Manager

Andy R.

Responsibilities

Own all case preparation, insulation layup/hand-off, robotic and manual liner application, external insulation closeout, and paint systems

Develop and qualify new liner formulations, spray/robotic dispensing programs, and cure cycles that meet bond-line strength, peel, and aging requirements across environmental extremes

Lead investigation and permanent elimination of liner/insulation

Implement real-time process monitoring (laser profiling, viscosity control, environmental logging) to achieve first-pass bond-line acceptance and zero paint rework

Drive transition from manual layup and brush/roller application to fully robotic lining cells, automated spray booths, and high-throughput paint lines

Specify, procure, and commission equipment including plural-component robotic dispensers, plasma/laser surface-treatment systems, and IR/UV cure ovens

Design or specify rotating case fixtures, expandable mandrels, robotic end-effectors, liner transfer pots, and clean-room layouts that support simultaneous processing of multiple large-diameter cases while maintaining ESD, FOD, and explosive safety standards

Author hazard analyses, SOPs, and safety submissions liners, solvent-based paints, and spray

Maintain strict VOC, HAP, and personnel exposure controls

Lead change-control for any material or process chemistry changes

Partner with Design Engineering during case and grain-design phases to ensure producible bond surfaces, accessible geometries, and compatible material systems

Generate PFMEAs, control plans, and qualification plans for new insulation/liner stacks

Execute first-article lining and paint on development and qualification motors

Serve as the primary point of contact for all bond-line and coating non-conformances

Perform or oversee pull tests, lap-shear testing, surface energy measurement, and cross-sectional analysis

Present technical data and corrective actions directly to Quality, EHS, and government/customer representatives

Qualification

Mechanical EngineeringAerospace EngineeringComposite MaterialsRobotic DispensingProcess DevelopmentStatistical Process ControlCreative Problem SolvingClear CommunicationHigh Initiative

Required

Bachelors degree in Mechanical, Aerospace, Chemical, Materials, or Manufacturing Engineering

Minimum 5 years of direct hands-on experience with composites and bonding, ideally with case internal insulation, liner application, and aerospace-grade coating systems