PCB Layout Engineer, Senior

About Castelion

Castelion is redefining defense development through rapid iteration, aggressive testing, and modern commercial manufacturing at scale. We design, build, and test next-generation long-range strike weapon systems to give the United States and its Allies a decisive advantage and deter future conflicts.

Position Overview

As a PCB Layout Engineer, you will independently own the layout and release of complex avionics printed circuit boards for hypersonic missile systems. You will partner closely with electrical, mechanical, systems, and manufacturing engineers to deliver flight-worthy hardware on aggressive schedules.

This role requires strong technical judgment, the ability to drive layout decisions across analog, digital, RF, and power domains, and comfort leading fabrication and assembly partners through DFM and production readiness. You will be expected to execute with minimal oversight while contributing to continuous improvement of Castelion's PCB design standards and processes.

Responsibilities

• Own PCB layout from initial placement through fabrication and assembly release for complex avionics hardware.
• Translate schematic intent and system requirements into robust, manufacturable PCB layouts.
• Drive component placement, stack-up definition, routing strategy, and constraint management across analog, digital, RF, and power domains.
• Lead PCB DFM/DFA reviews with fabrication and assembly vendors; close manufacturing issues through release.
• Develop and maintain PCB fabrication and assembly packages (Gerber/ODB++, BOMs, drawings).
• Interface directly with board houses to select materials, stack-ups, impedance targets, and DFX rules.
• Ensure designs meet IPC Class 3/3A and Castelion internal design standards.
• Maintain and expand the PCB component library; contribute to company-wide layout standards and best practices.
• Support signal integrity, power integrity, and EMI-focused layout trade studies.
• Collaborate with electrical, mechanical, systems, and software engineers through integration, test, and qualification.
• Support rapid iteration cycles and hardware re-spins in a fast-paced development environment.
• Provide technical guidance to junior PCB designers and review peer layouts.
• Communicate clearly across disciplines and sites to keep hardware on schedule.

Basic Qualifications

• 5 – 8+ years of experience in PCB layout and electronics hardware development.
• Strong proficiency with Altium (preferred) or equivalent professional PCB layout tools.
• Experience using mechanical CAD tools such as NX or SolidWorks for ECAD–MCAD coordination.
• Proven experience taking complex PCBs from concept through production release.
• Experience designing high-density, multi-layer PCBs (typically 10–20+ layers).
• Solid understanding of signal integrity, power distribution, grounding, EMI/EMC, and thermal considerations.
• Experience designing to IPC Class 3 / 3A requirements.
• Knowledge of PCB fabrication processes, materials, stack-ups, and manufacturing constraints.
• Experience working directly with PCB fabrication and assembly vendors.
• Strong problem-solving skills, attention to detail, and ownership mindset.
• Ability to operate effectively in highly cross-functional engineering teams.

Preferred Skills and Experience

• Experience in aerospace, missile systems, spaceflight, defense, or other high-reliability hardware environments.
• Hands-on experience with boards containing:
• Microcontrollers, DSPs, FPGAs, or ASICs
• High-speed digital interfaces (DDR3/4, SerDes, ADC/DACs)
• Power management and sensor interfaces
• RF and mixed-signal circuitry
• Familiarity with signal and power integrity tools (e.g., SiWave, HFSS, ADS, CST).
• Experience supporting EMI/EMC mitigation through layout techniques.
• Familiarity with relevant industry standards (e.g., MIL-STD, DO-254).
• Experience supporting hardware through environmental testing and qualification.
• Ability to mentor junior engineers and elevate team layout quality.

Additional Requirements

• Willingness to support extended hours or weekend work during critical integration, test, and flight milestones.

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.