Senior Thermal & TPS Integration Engineer

Why Castelion, Why NowCastelion 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 Thermal & TPS Integration EngineerWe are seeking multiple Senior Thermal & TPS Integration Engineers to design and deliver thermal protection solutions for Castelion’s long-range hypersonic strike vehicles. These roles are critical to ensuring vehicle survivability and performance in extreme aerothermal environments. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate TPS across the vehicle, including heat shields, control surface protection, and internal thermal insulation systems in a fast-paced, hardware-driven environment.ResponsibilitiesDesign and develop TPS across the vehicle, including heat shields, acreage TPS, and leading-edge protection systemsDesign TPS for control surfaces, including elevons, seals, and moving interface solutions that maintain performance under thermal and mechanical loadsDevelop internal thermal protection solutions, including insulators, blankets, and standoff systems to protect avionics and structuresLead the architecture and integration of TPS with primary structure, mechanisms, and subsystems, including attachment methods, gaps, and strain isolationPerform thermal and thermal-structural analyses to ensure performance under extreme aerothermal heating and transient environmentsWork closely with structures, materials, aerothermal, GNC, and manufacturing teams to ensure seamless system integrationDevelop and evaluate materials and configurations, including ceramics, carbon-carbon, ablatives, and insulating materialsConduct tolerance analysis and assess thermal expansion, deformation, and interface behaviorSupport prototyping, assembly, and hardware bring-up, including troubleshooting and root cause analysis of TPS performance issuesDefine and execute qualification and environmental test plans, including arc-jet, furnace, and flight testingOptimize designs for mass, thermal performance, durability, and manufacturabilityMentor junior engineers and contribute to best practices in TPS design and integrationPartner closely with program leadership to make technical trades aligned with mission successBasic QualificationsBachelor’s, Master’s, or PhD in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field5+ years of experience in thermal protection system design, analysis, and validation for aerospace or high-temperature applicationsStrong background in aerothermal environments, heat transfer, and high-temperature materialsExperience designing TPS for flight vehicles, including heat shields, control surfaces, or internal insulation systemsFamiliarity with TPS materials such as ceramics, carbon-carbon, ablatives, and insulating blanketsExperience with seals, gaps, and interface design in high-temperature, moving or constrained systemsProficiency in thermal and structural analysis tools (e.g., ANSYS, MATLAB, or equivalent)Experience with high-temperature testing methods (e.g., arc-jet, furnace, or similar)Experience with hardware build, test, and troubleshooting in a lab or flight hardware environmentStrong problem-solving mindset, thriving in a fast-paced, hardware-rich, high flight cadence environment Other DutiesPlease 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 PerksAll 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 StatementEmployment 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.