Additive Manufacturing Engineering Intern

About the Role

We are seeking an Additive Manufacturing Engineering Intern to support engineering design, advanced manufacturing processes, and data analysis. This role offers hands-on exposure to metal additive manufacturing, cold spray technology, robotics, and production systems supporting the development of the Terran R launch vehicle. The ideal candidate is curious, detail-oriented, adaptable, and eager to solve real-world engineering challenges in a fast-paced production environment.

Key Responsibilities

• Support the design, development, and readiness reviews of mechanical and manufacturing systems for additive hardware, robots, and sensors.
• Develop lightweight software tools and perform data analysis to support engineering and manufacturing decisions.
• Resolve manufacturing challenges through root-cause analysis and corrective actions.
• Develop and maintain standard operating procedures and work instructions for powder bed fusion (PBF) production operations.
• Troubleshoot live production issues and remove barriers to shop-floor operations.
• Improve and validate in-house additive manufacturing processes to support future Terran R launch vehicle production demands.
• Evaluate and integrate equipment and technologies to improve cold spray production repeatability and quality.
• Support process characterization to better understand cold spray deposition mechanisms.
• Plan, execute, and evaluate cold spray experiments involving new materials and components.
• Collaborate with engineering teams to troubleshoot process variability and identify improvement opportunities.
• Contribute to manufacturing infrastructure planning, process readiness, and continuous improvement.
• Coordinate project tasks, timelines, and deliverables across multiple teams.
• Compile and present technical findings with clear documentation and traceability.

Requirements & Tech Stack

• Currently pursuing a BS or MS in Mechanical, Manufacturing, Materials, Aerospace, Industrial Engineering, or a related engineering field.
• Proficiency in CAD software, with Siemens NX preferred, and the ability to generate engineering drawings.
• Experience with Python or a similar programming environment for data analysis and communicating results.
• Strong engineering fundamentals, including thermodynamics, material behavior, and mechanics of materials.
• Ability to define and implement processes from scratch and communicate technical information to diverse teams.
• Strong communication, collaboration, and problem-solving skills.
• Ability to work independently with minimal supervision, take initiative, and adapt to technical challenges in a production environment.
• Comfortable working in ambiguous situations, identifying problems, and developing practical solutions.
• Curious, detail-oriented, and motivated to learn about advanced manufacturing and rocket production.

Preferred Qualifications

• Familiarity with metal additive manufacturing technologies and alloy systems, including aluminum, nickel, copper, steel, and titanium.
• Knowledge of metal additive manufacturing methods such as Laser Powder Bed Fusion (LPBF), Wire Arc Additive Manufacturing (WAAM), and Directed Energy Deposition (DED).
• Understanding of Design for Additive Manufacturing (DFAM) for metal components.
• Basic knowledge of metallurgy, heat treatments, and post-processing techniques.
• Familiarity with motor control, robotics, and mechanical design fundamentals.
• Experience with CAD/CAE tools such as SolidWorks, ANSYS, or similar software for component design and simulation.
• Understanding of rocket propulsion system concepts.
• Knowledge of cold spray processes; hands-on cold spray experience is a plus but not required.
• Familiarity with materials and surface characterization techniques, including SEM, EDS, XRD, and hardness testing.
• Experience with toolpath generation for cold spray additive manufacturing.
• Experience in data science, engineering informatics, or project planning involving multiple stakeholders.

Compensation

$34–$42 per hour