{"id":2984808,"url":"https://alion.io/job/castelion-manufacturing-engineer-advanced-composite-machining","title":"Manufacturing Engineer – Advanced Composite Machining","company":{"id":1795053,"name":"Castelion","domain":"castelion.com","url":"https://alion.io/company/castelion","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":null},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":null,"employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":[],"countries":[],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":77000,"max_usd":180000,"period":"year","method":"role_country_seniority_unknown","sample_n":15150},"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Siemens NX","optional":false}],"status":"live","first_seen_at":"2026-10-14T23:49:58Z","employer_posted_date":"2026-10-14","last_verified_at":"2026-11-04T22:58:02Z","board_verified":true,"closed_at":null,"days_open":21,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":21},"description":"Why Castelion, Why Now \nCastelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability. \nThis is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function. \nManufacturing Engineer - Advanced Composite Machining \nAbout the Role\nWe are seeking an experienced, hands-on CNC Machinist / Manufacturing Engineer specializing in 5-axis machining and advanced composite materials. This role combines advanced CAM programming, machine setup and operation, tooling strategy, and manufacturing process development.\nThe ideal candidate will have extensive experience programming and operating 5-axis CNC machines using Siemens NX CAM and/or Mastercam, with direct experience machining advanced materials such as carbon-carbon, phenolic composites, and carbon-silicon carbide (C/SiC).\nA major focus of this position is cutting tool selection and optimization. The successful candidate will understand how tool geometry, substrate, coating, cutting-edge preparation, toolpath strategy, feeds, speeds, and tool engagement affect machining quality, tool life, cycle time, and overall process capability.\nThis individual will help develop robust machining processes for complex components, working closely with engineering, quality, and manufacturing teams to transition R&D hardware into repeatable production.\nKey Responsibilities\n5-Axis CNC Programming & Machining\nDevelop, program, simulate, and prove out complex 5-axis CNC machining operations.\nCreate advanced CAM toolpaths using Siemens NX CAM and/or Mastercam.\nOptimize toolpaths for material removal, surface finish, dimensional accuracy, cycle time, and machine utilization.\nGenerate, verify, and maintain CNC programs, post-processed code, setup sheets, and machining documentation.\nSet up and operate 5-axis CNC machines, including workholding, tooling, probing, and process verification.\nTroubleshoot toolpath, machining, vibration, surface quality, and dimensional issues.\nApply appropriate strategies for complex geometries, thin sections, intricate features, and close-tolerance components.\nCutting Tool Selection & Optimization - Primary Focus\nSelect and validate cutting tools specifically suited to carbon-carbon, phenolic, C/SiC, and other advanced composite materials.\nEvaluate tool geometry, cutting-edge design, substrate, coatings, abrasive-wear resistance, and tool construction.\nDetermine appropriate feeds, speeds, chip loads, stepovers, stepdowns, and tool engagement strategies for each material and operation.\nEvaluate diamond tooling, PCD tooling, carbide tooling, and other specialized cutting tools as appropriate to the material and application.\nDevelop tooling strategies that minimize fiber pullout, delamination, edge breakout, chipping, thermal damage, and dimensional instability.\nEstablish tool-life expectations, wear limits, replacement criteria, and tooling performance standards.\nConduct tooling trials and document results to compare tool life, surface finish, dimensional accuracy, cycle time, and cost per part.\nWork directly with cutting tool suppliers to evaluate new tooling technologies, conduct trials, and resolve machining challenges.\nStandardize tooling selections and cutting parameters to improve process repeatability and reduce unnecessary tooling costs.\nBuild a structured tooling database containing tool specifications, approved applications, cutting parameters, performance data, and lessons learned.\nAdvanced Composite Machining\nMachine carbon-carbon, phenolic, and carbon-silicon carbide components using appropriate material-specific machining strategies.\nDevelop processes for abrasive, brittle, and fiber-reinforced materials with unique cutting and failure characteristics.\nIdentify and mitigate defects associated with edge chipping, fiber damage, breakout, surface finish, and dimensional variation.\nDevelop suitable workholding, fixturing, support, and datum strategies for composite components.\nEstablish appropriate dust extraction, housekeeping, material handling, and exposure controls for composite machining operations.\nSupport prototype development and transition proven processes into repeatable production.\nManufacturing Engineering & Process Development\nDevelop manufacturing plans, setup sheets, tooling lists, work instructions, and standard operating procedures.\nCollaborate with design engineering to provide design-for-manufacturability feedback.\nSupport first-article inspections, process validation, root-cause investigations, and corrective actions.\nDevelop repeatable machining processes that improve throughput, reduce scrap, and support production scaling.\nEstablish standard machining methods, programming practices, and tooling strategies across the machine shop.\nUse data-driven continuous improvement to improve OEE, reduce cycle time, and increase first-pass yield.\nRequired Qualifications\nExtensive hands-on experience with 5-axis CNC milling.\nDemonstrated CAM programming experience using Siemens NX CAM and/or Mastercam.\nDirect experience machining advanced composites, preferably carbon-carbon, phenolic, or C/SiC.\nStrong expertise in cutting tool selection, cutting parameters, and machining process optimization.\nProven ability to develop and troubleshoot complex machining operations independently.\nStrong understanding of engineering drawings, GD&T, CAD models, and dimensional inspection.\nExperience with workholding, fixturing, CNC setup, program prove-out, and process validation.\nStrong analytical and problem-solving skills, with the ability to use machining data to improve performance.\nCommitment to safe machining practices, particularly around composite dust and material-specific hazards.\nPreferred Qualifications\nExperience with both Siemens NX CAM and Mastercam.\nExperience with diamond, PCD, carbide, or other specialized tooling for abrasive and brittle materials.\nExperience machining aerospace, defense, propulsion, thermal protection, or high-performance composite components.\nExperience developing tool-life studies, tooling cost models, and standardized cutting parameter libraries.\nExperience with CNC post-processors, simulation, collision avoidance, and complex 5-axis verification.\nExperience taking parts from R&D prototypes through process qualification and production release.\nWhat Success Looks Like\nEstablish validated tooling strategies for each composite material and machining application.\nImprove tool life, surface quality, dimensional consistency, and machining productivity.\nReduce scrap, rework, tool failures, and unplanned machine downtime.\nEstablish standardized NX CAM/Mastercam programming methods and tooling documentation.\nDevelop repeatable, scalable machining processes for advanced composite components.\nBuild a data-driven approach to tooling selection based on demonstrated machining performance rather than trial and error.\nIdeal Candidate\nThe ideal candidate is a technical expert who can move seamlessly between CAM programming, cutting tool selection, machine operation, and manufacturing engineering. They understand that successful composite machining depends on the complete process: the material, cutting tool, toolpath, workholding, machine capability, and process controls.\nThey should be comfortable working hands-on in an R&D environment, running tooling trials, solving difficult machining problems, and developing documented processes that other machinists and programmers can reliably execute.\nCastelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details. \nOther Duties \nPlease 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. \nAdditional Eligibility Requirements \nThis 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. \nAffirmative Action/EEO Statement \nCastelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law. \nCastelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact . Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law. \nCastelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation. \nEAR/ITAR Requirements \nThis position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.","description_format":"text","description_chars":10328,"description_truncated":false,"requirements":{"experience_years_min":null,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":null,"security_clearance":true,"languages":[]},"benefits":[],"hiring_locations":[{"name":"United States","iso":"US","kind":"country"}],"hiring_excludes":[],"relocation_offered":false,"industries":["Missiles","Defense Manufacturing"],"lifecycle":[{"event":"open","at":"2026-10-21T08:14:48Z"}],"visa":[],"liveness":{"score":78,"band":"hot","label":"Hiring now","p_open":1,"p_active":0.865,"p_room":0.9,"age_days":20,"expected_fill_days":46,"reasons":["conf:2","velocity","win:mid","comp:brand"],"computed_at":"2026-11-04T06:34:25Z"},"pay":null,"html_url":"https://alion.io/job/castelion-manufacturing-engineer-advanced-composite-machining","json_url":"https://alion.io/job/castelion-manufacturing-engineer-advanced-composite-machining.json","meta":{"generated_at":"2026-11-05T01:12:02Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":1399,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-11-06T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":1795053},"rest":"https://alion.io/mcp/rest/get_company?id=1795053"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fcastelion-manufacturing-engineer-advanced-composite-machining"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fcastelion-manufacturing-engineer-advanced-composite-machining"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fcastelion-manufacturing-engineer-advanced-composite-machining"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/castelion-manufacturing-engineer-advanced-composite-machining\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fcastelion-manufacturing-engineer-advanced-composite-machining"}],"agent":{"mcp":"https://alion.io/mcp/jobs","mcp_open":"https://alion.io/mcp/open","next":[{"tool":"get_job","arguments":{"id":2984808}},{"tool":"search_jobs","arguments":{"company":"castelion.com","detail":"compact"}},{"tool":"match_people","arguments":{"job_id":2984808},"note":"people open to offers who fit this vacancy"}],"note":"The same data through MCP tools: https://alion.io/mcp/open needs no sign-in (compact searches, postings, people); https://alion.io/mcp with an Alion account has everything. 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