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Castelion • Torrance, California, United States
Role & seniority
Stack / tools
Actuator test environments, hardware-in-the-loop (HIL), test fixtures, data acquisition
Programming: Python, C++, Protobuffs
Communication protocols: CAN, RS-422/485, SPI, Ethernet, Automotive Ethernet
Test domains: environmental stress (vibe, thermal, EMI), ESS, fault injection
Instrumentation: motors, load cells, encoders, motion-control loops
Top 3 responsibilities
Develop and execute actuator test plans across component to system levels; build and run test rigs simulating flight conditions
Validate performance metrics (torque, response, bandwidth, power, thermal) under nominal and fault scenarios; log with traceability
Lead root-cause investigations; drive qualification and environmental testing campaigns for flight hardware
Must-have skills
BS/MS in Mechanical, Mechatronics, Aerospace, or Electrical Engineering; 4+ years testing actuators/motion control in aerospace/defense
Hands-on with test setups using motors, load cells, encoders; strong data logging and analysis
Familiarity with embedded controls and protocols (CAN, RS-422/485, SPI, Ethernet); proficient with Python/C++
Nice-to-haves
Experience with high-force/high-precision actuators (TVC, flight control surfaces) and flight-like test environments
Fault injection, reliability qualification, ESS exposure; flight test or launch ops background
Additional C/C++ or Python tooling for custom tests
Location & work type
About Castelion
Castelion is bringing a new approach to defense development and production: one that focuses on short, iterative design cycles, rapid testing in development, and modern commercial manufacturing strategies for production at scale. We're designing, building, and testing next generation long range strike weapons systems to give America and its Allies a definitive edge and deter future conflicts. Senior Avionics Test Engineer We are looking for a Senior Avionics Test Engineer to own the validation and performance characterization of our control actuation systems the critical interface between control commands and physical motion on our flight vehicles. You will lead the development of rigorous test infrastructure, design and execute test campaigns, and help define the performance envelope of every actuator that flies. This role blends hands-on testing with systems-level thinking. You'll work closely with controls, software, avionics, and mechanical teams to ensure our actuation hardware is verified against realistic, mission-representative conditions. Responsibilities Develop and execute comprehensive actuator test plans across component, subassembly, and integrated system levels. Build test fixtures, HIL environments, and automated test rigs to simulate flight conditions and actuator load profiles. Validate performance metrics such as torque, response time, bandwidth, power draw, and thermal behavior under nominal and fault scenarios. Instrument and log actuator tests for precise characterization and traceability. Lead root-cause investigations for performance anomalies or test failures. Collaborate with mechanical and control systems teams to refine actuator designs based on test results and failure data. Drive qualification testing and environmental testing campaigns (vibe, thermal, EMI) for flight hardware. Basic Qualifications
B. S. or M.S. in Mechanical, Mechatronics, Aerospace, or Electrical Engineering.
Hands-on rigor: deep understanding of systems through direct testing and failure analysis.
Autonomy and ownership: you don't wait for direction you seek out what needs to be tested and make it happen. High standards for reliability, data quality, and test repeatability.
Systems-level thinking: understanding how actuator behavior affects broader vehicle performance. Leadership Qualities Bias to Action and Creative Problem Solving. Desire and experience questioning assumptions in ways that lead to break through ideas that are ultimately implemented. Successfully bring in applicable processes/concepts/materials from other industries to achieve efficiency gains. Ability to personally resolve minor issues in development without requiring significant support. High Commitment, High Initiative. A successful candidate will have a genuine passion for Castelion's mission and consistently look for ways to contribute to the company's technical goals and prevent hardware blockers. Ability to work in a fast paced, autonomously driven, and demanding atmosphere. Strong sense of accountability and integrity. Clear Communicator. Proactively communicates blockers. Trusted in previous roles to be voice of company with regulators, suppliers, gate keepers and customers. Capable of tactfully managing relationships with stakeholders to achieve company-desired outcomes without compromising relationships. Emails, IMs and verbal interactions are logical, drive clarity, and detailed enough to eliminate ambiguity. 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. 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. All employees are granted long-term stock incentives as part of their employment at Castelion. All employees receive access to comprehensive medical, vision, and dental insurance, and the company offers four weeks of paid time off per year.