Staff Dimensional Metrology Engineer

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 design, build, and test next generation weapon systems to give America and its Allies a definitive edge in defense capabilities.

Staff Dimensional Metrology Engineer

The Dimensional Metrology Engineer will serve as the hands-on technical authority for applied dimensional measurements across Castelion. You will collaborate with design, manufacturing, test, and quality teams to integrate metrology early in development for better risk management, process characterization, and verification. You will drive metrology-as-a-service across the company, develop novel measurement solutions, mentor teams on cutting-edge dimensional measurement technology, and establish scalable metrology infrastructure to support high-rate production as we scale.

Responsibilities

Metrology Technology & Infrastructure

• Serve as the hands-on technical authority for applied dimensional measurement, establishing best practices and standards for the site.
• Develop and deploy novel, fit-for-purpose metrology technology applications to solve emerging measurement challenges.
• Design or procure new measurement equipment as required to achieve required inspections with maximum efficiency and capability.
• Support measurement system analysis (MSA) for evaluation of internal applications and smart CAPEX decisions.
• Oversee the calibration management program, ensuring measurement devices maintain certification schedules through qualified service providers and that internal metrology processes comply with quality standards.
• Pursue automation solutions that enable reliability engineers and citizen data collectors to be power users of metrology tools, achieving expert-level inspection outputs, while standing up data infrastructure to democratize metrology data access across internal teams.

Design Integration & Manufacturing Support

• Collaborate with design, manufacturing, test, and quality teams to integrate metrology early in development for better risk management, process characterization, and verification.
• Participate in Design and Build Reviews to ensure design for measurability and dimensional verification.
• Perform dimensional analysis and measurement studies to validate design intent, manufacturing capability, and assembly fit.
• Support Reliability Engineers with CAPA (Corrective Action Preventive Action) events with the ability to measure as-built hardware.
• Investigate the connection between as-built condition, as-tested performance, and aerodynamic simulation performance.
• Develop metrology strategies for characterizing complex geometries and materials (composites, additive manufacturing, high-precision assemblies).
• Drive continuous improvement initiatives to enhance measurement accuracy, repeatability, and efficiency to enable high-rate manufacturing at Castelion.

Leadership & Mentorship

• Mentor leaders, engineers, and technicians on the art of the possible for dimensional measurement technology and capabilities the industry has to offer.
• Drive metrology-as-a-service across the company, establishing a consultative model for supporting internal customers.
• Facilitate creation of training plans and materials to build metrology competency across the organization.
• Proactively communicate measurement capabilities, limitations, and recommendations to cross-functional stakeholders.

Requirements and Skills

Minimum Requirements:

• 7+ years of hands-on experience in dimensional metrology, with expertise in advanced measurement technologies (CMM, laser scanning, photogrammetry, optical systems, etc.).
• Expert-level proficiency with Polyworks or similar metrology software platforms.
• Demonstrated experience scripting and automating inspection workflows to enable scalable, repeatable measurement processes.
• Strong foundation in GD&T (Geometric Dimensioning and Tolerancing) and measurement uncertainty analysis.
• Proven track record of developing novel metrology solutions for complex manufacturing challenges.

Preferred Qualifications:

• Experience in aerospace, defense, or high-precision manufacturing environments.
• Hands-on experience with photogrammetry systems and target tracking applications.
• Experience standing up metrology data management systems (Polyworks Dataloop or equivalent).
• Knowledge of measurement system analysis (MSA), process capability studies, and statistical quality tools.
• Experience supporting high-rate production environments with scalable metrology strategies.
• Familiarity with advanced materials and manufacturing processes (composites, CMC, additive manufacturing).
• Experience correlating dimensional measurement data with performance testing and simulation results.
• Background in optical measurement systems, structured light scanning, or coordinate measuring machines (CMM).

Leadership Qualities

Bias to Action and Creative Problem Solving. Desire and experience questioning assumptions in ways that lead to breakthrough ideas that are ultimately implemented. Successfully bring in applicable measurement technologies, processes, and concepts from other industries to achieve efficiency gains. Ability to personally resolve measurement challenges 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 measurement capabilities, blockers, and recommendations. Trusted in previous roles to be the voice of metrology with design, manufacturing, and quality teams. 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.