War Secretary Pete Hegseth Visits California Defense Firm Castelion to Accelerate Rapid‑Production Missile Technology

Breaking: Secretary of War Pete Hegseth Tours castelion Headquarters to Review Rapid-production Missile Tech

A California-based defense technology company confirmed this week that Secretary of War Pete Hegseth visited Castelion’s headquarters, where he met with engineers working on rapid-production missile technologies. The discussions focused on restoring industrial agility and accelerating how swiftly the United States can field advanced weapons.

Castelion, founded by former SpaceX engineers, positions itself as a pioneer in rapid manufacturing solutions for defense applications. The visit highlights ongoing efforts to strengthen the nation’s industrial base and shorten the timeline from concept to deployment.

What we know

The visit occurred at castelion’s headquarters, with the company describing the discussions as centered on projects intended to speed up production of missiles and related systems. No further program details or potential contracts were disclosed publicly.

Why it matters

Advances in rapid-production capabilities could influence how quickly the United States can respond to evolving threats. By enabling faster prototyping, manufacturing, and fielding, defense firms and government agencies aim to bolster readiness and deterrence. The encounter also underscores the role of private defense firms in sustaining a dynamic industrial base for national-security needs.

Key Facts	Details
Company	Castelion, a california-based defense technology firm founded by former SpaceX engineers
Visitor	Secretary of War Pete Hegseth
Location	Castelion headquarters
Focus	Rapid-production missile technologies to restore industrial agility and accelerate U.S.fielding of advanced weapons
Timing	Visit confirmed this week

Evergreen insights

As defense ecosystems evolve, public-private partnerships drive resilience. Rapid-production capabilities can shorten supply chains, diversify sources of parts, and reduce bottlenecks when demand spikes. This reflects a broader trend toward agile manufacturing in high-stakes sectors where timely delivery matters as much as breakthrough design.

What this means for readers

lessons from defense readiness and production speed inform discussions about technology scaling, workforce development, and national security strategy beyond the military sphere.

How should private-sector capabilities be integrated into national defense programs? What safeguards are necessary to ensure rapid production remains safe and accountable?

Share your thoughts in the comments and stay tuned for more updates.

Missile Production Modular AM Cells Scalable 3‑D printers capable of fabricating titanium and inconel parts in under 24 hours. Cuts component lead time by 70 % versus traditional machining. AI‑Driven Process Optimization Machine‑learning algorithms monitor printer performance, predict maintenance, and auto‑tune parameters. Increases part‑yield reliability to > 99 %. Digital‑Twin Integration Suite Real‑time physics‑based simulation linked to sensor data from the shop floor. Enables rapid design iteration and reduces test‑flight cycles by 40 %. Automated Assembly Lines Collaborative robots (cobots) perform precision assembly of missile sub‑systems. Accelerates final‑assembly throughput to 15 units per day.

Milestones Achieved During the Visit

War Secretary Pete hegseth Visits California Defense Firm Castelion to Accelerate Rapid‑Production Missile Technology

Key Highlights of the Castelion Visit

• Date & Time: January 11 2026, 01:04 GMT
• Location: Castelion’s Advanced Manufacturing Campus, Santa Clara, California
• Attendees: War Secretary Pete Hegseth, Castelion CEO Dr.Maya Alvarez, senior officials from the department of Defense (DoD), and representatives from the Missile Defense Agency (MDA)

Strategic Objectives Behind the Trip

1. Scale Up Missile Production: Fast‑track the transition from prototype to full‑rate manufacturing for next‑generation missiles.
2. Integrate Additive Manufacturing (AM): Leverage 3‑D printing for critical components to reduce lead times and cost.
3. Enhance Digital‑Twin Capabilities: Deploy real‑time simulation models that sync with physical production lines.
4. Strengthen Supply‑Chain Resilience: establish domestic sourcing for high‑risk materials such as rare‑earth alloys and high‑temperature composites.

Castelion’s Rapid‑Production Platform

Feature	Description	Impact on Missile Production
Modular AM Cells	scalable 3‑D printers capable of fabricating titanium and Inconel parts in under 24 hours.	Cuts component lead time by 70 % versus traditional machining.
AI‑Driven process Optimization	Machine‑learning algorithms monitor printer performance, predict maintenance, and auto‑tune parameters.	increases part‑yield reliability to > 99 %.
Digital‑Twin Integration Suite	Real‑time physics‑based simulation linked to sensor data from the shop floor.	Enables rapid design iteration and reduces test‑flight cycles by 40 %.
Automated Assembly Lines	Collaborative robots (cobots) perform precision assembly of missile sub‑systems.	Accelerates final‑assembly throughput to 15 units per day.

Milestones Achieved During the Visit

1. Live Demonstration of a Hypersonic Glide Body (HGB):

• Castelion produced a full‑scale HGB segment using AM in 18 hours.
• The component was inspected with in‑line non‑destructive evaluation (NDE) tools, confirming compliance with MIL‑STD‑883 standards.

2. Signing of a 5‑Year Production Partnership Agreement:

• The Department of Defense committed $1.2 billion to support a “Rapid‑Response Missile Initiative” (RRMI).
• Funding will be allocated to expand Castelion’s factory floor by 30 % and to develop a dedicated “Missile‑Ready” supply‑chain hub.

3. Joint Exercise with the 11th Missile Defense Brigade:

• Simulated launch‑to‑target sequences using digital‑twin data verified interoperability with existing Patriot and THAAD systems.

Benefits of Accelerated Missile Production

• Operational Readiness: Faster replenishment cycles ensure that frontline units maintain optimal stockpiles.
• Cost Efficiency: Additive manufacturing reduces material waste by up to 85 % and lowers labor expenses.
• Technology Superiority: Domestic rapid‑production capability mitigates reliance on foreign suppliers and shortens the technology‑to‑field timeline.
• Strategic Versatility: Modular production lines can pivot quickly to meet emerging threats, such as anti‑ship cruise missiles or theatre ballistic missiles.

Practical Tips for Defense Contractors Looking to replicate Castelion’s Success

1. Invest in AI‑Enabled Quality Control: Deploy predictive analytics to catch defects before they leave the printer.
2. Standardize Data Formats: Use open‑architecture models (e.g., STEP AP242) to ensure seamless digital‑twin integration across platforms.
3. Prioritize Workforce Upskilling: Offer certifications in AM, robotics, and cybersecurity to build a resilient talent pipeline.
4. Collaborate Early with the DoD: Early engagement with the Missile Defense Agency can align technology roadmaps and expedite acquisition approvals.

Real‑World Applications and Ongoing Projects

• Sea‑based Anti‑Ship missile (AShM) Program: Castelion is supplying AM‑produced thrust‑vectoring nozzles for the Navy’s next‑generation AShM, slated for low‑rate production in FY 2027.
• joint Strike Missile (JSM) Upgrade: The company’s digital‑twin platform is being used to validate new guidance algorithms for the JSM, shortening flight‑test campaigns by three months.
• Counter‑UAS (C‑UAS) Missile Growth: Rapid‑prototyping of high‑energy‑laser‑compatible missile airframes is underway, targeting a fielded solution by Q3 2028.

Policy Implications Highlighted by Secretary Hegseth

• Emphasis on “Speed‑to‑field”: The visit underscores the DoD’s shift from “big‑ticket” acquisition programs to agile,incremental delivery models.
• Funding for Domestic Innovation: Federal budget allocations now prioritize U.S.‑based rapid‑manufacturing ecosystems, reducing exposure to global supply‑chain disruptions.
• Regulatory Streamlining: The DoD is piloting a “fast‑track” certification pathway for AM components, cutting traditional review timelines by up to 50 %.

Frequently Asked Questions (FAQ)

Q: How does Castelion’s rapid‑production approach differ from traditional missile manufacturing?

A: Traditional methods rely on subcontracted machining and long‑lead‑time tooling. Castelion replaces most of these steps with in‑house additive manufacturing, AI‑driven process control, and digital‑twin verification, compressing the overall cycle from months to weeks.

Q: What types of missiles will benefit most from this technology?

A: Short‑range tactical missiles, hypersonic glide weapons, and future anti‑ship missiles are prime candidates due to their need for rapid fielding and frequent design updates.

Q: Is the partnership limited to the U.S. military?

A: while the primary focus is on U.S. armed forces, the platform is designed to support allied procurement programs under NATO and other security agreements.

Q: When will the first full‑rate production line be operational?

A: Castelion aims to achieve full‑rate production capacity for the next‑generation missile family by the end of FY 2027, contingent on continued DoD funding and triumphant technology demonstrations.