R&D Technician

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.

R&D Technician

We are seeking an R&D Technician to support hands-on solid rocket motor (SRM) manufacturing and testing operations at Castelion's development site. Reporting to the Development Site Operations Manager, this role is critical to the safe and effective execution of propellant processing, motor assembly, test setup, and development testing for hypersonic programs including Blackbeard. You will work closely with manufacturing engineers, test engineers, and operations leadership to execute procedures, operate equipment, collect data, and maintain a high standard of safety and quality in a fast-paced R&D environment involving energetic materials.

Responsibilities

• Execute hands-on propellant manufacturing and SRM assembly tasks according to approved work instructions, including material handling, mixing support, casting operations, curing, and component integration.
• Support test setup, instrumentation installation, hardware preparation, and execution of static fire, environmental, functional, and other development tests under the direction of test engineers and the Site Operations Manager.
• Operate, monitor, and perform basic maintenance on manufacturing and test equipment (mixers, casting systems, ovens, test stands, data acquisition systems, and related tooling).
• Collect, document, and organize process and test data; assist with post-test hardware recovery, inspection, and data packaging.
• Strictly follow all energetic materials handling, explosive safety, lockout/tagout, and site-specific safety protocols; actively contribute to a strong safety culture.
• Maintain cleanliness, organization, and readiness of manufacturing and test areas; support 5S and continuous improvement activities.
• Assist with equipment qualification, process trials, procedure validation, and troubleshooting under engineering guidance.
• Prepare and stage materials, tooling, and hardware for builds and tests; support inventory control and material tracking.
• Collaborate daily with engineers, operators, and the Site Operations Manager to meet schedule, quality, and safety objectives.
• Support cross-training and knowledge sharing as the development site scales capabilities and processes.

Basic Qualifications

Education:

• High school diploma or equivalent required. Associate's degree, technical certificate, or equivalent military/technical training in manufacturing, mechanical, electrical, or related field preferred.

Experience:

• 3+ years of hands-on experience in manufacturing, assembly, testing, or operations in aerospace, defense, propulsion, chemical processing, or other high-hazard industrial environments.
• Experience working with energetic materials, hazardous chemicals, or high-consequence processes is highly desirable.

Technical Skills

• Ability to follow detailed work instructions, engineering drawings, and test procedures accurately.
• Hands-on mechanical aptitude with experience using hand tools, power tools, measuring instruments, and basic shop equipment.
• Comfort operating or supporting process equipment (mixers, ovens, presses, or similar) and test-related systems.
• Basic familiarity with data collection, instrumentation, or computer-based logging systems.
• Strong attention to detail, documentation discipline, and ability to work safely in a regulated environment.
• Physical ability to lift and handle hardware (typically up to 50 lbs), work in standing positions for extended periods, and operate in industrial/test environments.

Preferred Skills and Experience

• Direct experience supporting solid rocket motor, propellant, munitions, or missile manufacturing or testing.
• Background in aerospace or defense R&D or production environments.
• Experience with static fire testing, environmental testing, or range operations support.
• Prior work in energetic materials facilities or with ATF/DoD explosive safety requirements.
• Familiarity with lean manufacturing, 5S, or continuous improvement practices.
• Experience in a fast-paced startup or development environment.

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.

Benefits And Perks

All full-time employees are granted meaningful long-term equity, sharing in the company's significant growth trajectory. We offer four (4) weeks of paid time off, ten (10) company-paid holidays, and comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage, along with dental and vision plans. We also provide paid parental leave to support growing families, a $100 monthly fitness stipend to promote health and performance, and onsite EV charging for convenience. In addition, employees enjoy perks like catered meals, company-covered food during high-demand periods, and a fully stocked kitchen to stay fueled throughout the day.

While this position does not currently require a U.S government-issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S. government–issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance.

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.