Additive Manufacturing Engineer Intern

About the Role

We are looking for an Additive Manufacturing Engineer Intern to support engineering design, manufacturing, and data analysis.

Program Highlights

• Resolve manufacturing challenges and issues by implementing root cause corrective actions related to additive products and assets.
• Author and maintain standard operating procedures and work instructions for PBF production operations.
• Clear barriers to production operations with live issue resolution on the shop floor.

Key Responsibilities

• Support the design, development, and readiness reviews of mechanical and manufacturing systems for additive hardware, robots, and sensors.
• Build lightweight software tools and run data analyses to drive informed engineering and manufacturing decisions.
• Contribute to manufacturing and infrastructure planning, identifying improvements for process readiness.
• Collaborate across mechanical, manufacturing, process, and robotics engineering teams to deliver innovative solutions.
• Assist in compiling and presenting technical findings, ensuring clarity and traceability in communication.
• Coordinate and track project tasks, timelines, and deliverables, contributing to cross-functional program management.
• Develop, improve, and validate in-house additive manufacturing processes towards scaling future Terran R launch vehicle demand.
• Evaluate and integrate new equipment or technologies to support cold spray production repeatability and quality.
• Support process characterization efforts to improve fundamental understanding of cold spray deposition mechanisms.
• Support experimental design, execution, and evaluation of cold spray trials for new materials and components.
• Collaborate with engineers to troubleshoot process variability and identify improvement opportunities.

Requirements & Tech Stack

• Pursuing a BS or MS in Engineering (Mechanical, Manufacturing, Materials, or related field).
• Proficient in CAD software (Siemens NX preferred) with ability to generate engineering drawings.
• Comfortable working with Python or similar coding environments to analyze data and communicate results.
• Strong communicator who thrives in collaborative, interdisciplinary environments and takes initiative with minimal supervision.
• Obtaining BS or MS in aerospace, mechanical, manufacturing, or industrial engineering.
• Demonstrated ability to define and implement a process from scratch and effectively communicate to a diverse team.
• To be successful in this role, you need to be able to thrive in ambiguity, identify problems and quickly resolve them, and provide definition to the previously undefined.
• You will need to balance a scrappy, get-it-done attitude with a vision for the long-term processes required for scaling and efficiency!
• Curious, detail-oriented, and eager to learn about advanced manufacturing and rocket manufacturing.
• Strong understanding of engineering fundamentals such as thermodynamics, materials behavior, and mechanics of materials.
• A collaborative problem-solver with the ability to adapt to technical challenges in a production environment.

Qualifications

• Familiarity with metal additive manufacturing technologies and alloy systems (aluminum, nickel, copper, steel, titanium, etc.).
• Basic knowledge of metallurgy, heat treatments, and post-processing techniques.
• Understanding of motor control, robotics, and mechanical design fundamentals.
• Experience in data science, informatics, or project planning involving multiple stakeholders.
• Knowledge of design for additive manufacturing (DFAM) of metal components.
• Familiarity with additive manufacturing technologies, specifically metal AM technologies like Laser-Powder Bed Fusion, WAAM, DED, etc.
• Familiarity with rocket propulsion system concepts.
• Strong understanding of cold spray process.
• Hands-on cold spray experience is preferred, not required.
• Knowledge of surface and materials characterization techniques (SEM, EDS, XRD, hardness testing).
• Experience with CAD/CAE tools (SolidWorks, ANSYS, or similar) for component design and simulation.
• Experience with toolpath generation for cold spray additive manufacturing.