Manufacturing Engineering Intern

BlueHalo; Pottstown (Montgomery County); On-site; USD 28,000 - 39,000; Full time

Benefits offered by this job

Housing stipend

Top internship program recognition (Y

Job summary

BlueHalo is seeking a Manufacturing Engineering Intern for a 12-week, onsite summer program in Pottstown, PA. You will assist in manufacturing system design, data analysis, and process improvement under experienced engineers.

This paid internship emphasizes Lean and Six Sigma, documentation, and cross‑functional collaboration, with relocation/housing support possible for eligible students.

Qualifications

• Pursuing a Bachelor’s in Industrial or Mechanical engineering.
• Some coursework or experience related to manufacturing, process improvement, or quality control.
• Lean Manufacturing and Six Sigma knowledge a plus.
• Familiarity with electro-mechanical manufacturing, drawings, and BOM preferred.
• Proficient in MS Office; CAD/Visio/Minitab a plus.
• Willingness to travel up to 10% to supplier sites.

Responsibilities

• Assist in supporting and improving manufacturing processes with focus on efficiency and quality.
• Help implement Lean and Six Sigma for continuous improvement.
• Analyze production data—yields, capacity, cost, and process capability.
• Document standard work hours, sequences, and assembly procedures.
• Support creation of work instructions and process documentation.
• Participate in root cause analysis of materials, design, equipment, and personnel.

Skills

Problem solving

Root cause analysis

Teamwork & communication

Task management

Initiative & responsibility

Commitment to learning

Education

Bachelor’s degree in Industrial or Mechanical Engineering

Tools

Visio

Minitab

SolidWorks

Job description

Worker Type

Supplemental

Job Description

Manufacturing Engineering Intern

Summer Internship Program

Our paid Summer Internship Program is designed to provide students with an immersive, hands‑on experience within the aerospace and defense industry. Interns work alongside AV team members on meaningful projects involving cutting‑edge technology while developing professional relationships, strategic problem‑solving skills, and practical experience in a full‑time work environment.

This is a 12‑week, onsite program intended for highly motivated and passionate students who are currently enrolled in college or are recent graduates. Applicants must have a minimum 3.0 GPA, with a preference for students at the junior level or above.

Our program has been recognized by Yello and WayUp as one of the Top 100 Internship Programs in the United States for multiple years.

Depending on the team and location, students who are willing to relocate for their internship may be eligible for a relocation and housing reimbursement stipend.

This position will site onsite in our Pottstown, PA office and will focus on UXS / VideoRay products.

Summary

As a Manufacturing Engineering Intern, you will support the design and operation of manufacturing systems for AV Unmanned Air Vehicles. Under the guidance of experienced manufacturing engineers, you will assist in analyzing production processes and data, help optimize manufacturing workflows, and contribute to continuous improvement initiatives using Lean Manufacturing and Six Sigma principles. This internship provides hands‑on experience in manufacturing process design, factory planning, and production support.

Position Responsibilities

• Assist in supporting and improving manufacturing processes with a focus on efficiency and quality


• Help implement Lean Manufacturing principles and apply Six Sigma methods to support continuous improvement efforts


• Analyze production data such as yields, capacity, cost, and process capability to identify opportunities for improvement


• Support establishment and documentation of standard work hours, sequences, and assembly procedures


• Help generate and update work instructions and other documentation controlling manufacturing processes


• Participate in root cause analysis and problem‑solving activities related to materials, design, equipment, and personnel


• Assist in manufacturing capacity planning and factory layout design for improved efficiency


• Support cost estimation activities for new tooling, fixtures, and production equipment


• Collaborate with design engineering teams on Design for Manufacturing (DFM) and reliability analysis


• Participate in cross‑functional improvement projects involving engineering and suppliers to enhance cost, cycle time, and quality


• Support Design Failure Modes and Effects Analysis (DFMEA) and Process FMEA (PFMEA) activities


• Provide input to engineering regarding manufacturing considerations for design concepts and specifications


• Gain hands‑on experience supporting production floor activities, including assembly and integration processes


• Other duties as assigned

Basic Qualifications

• Currently pursuing a Bachelor’s degree in Industrial, Mechanical, or a related engineering field


• Some coursework or experience related to manufacturing, process improvement, or quality control


• Familiarity with Lean Manufacturing and Six Sigma principles is a plus


• Basic knowledge of electro‑mechanical manufacturing, technical drawings, and Bill of Materials is preferred


• Proficient in Microsoft Office (Word, Excel, PowerPoint, Outlook); experience with Visio, Minitab, or CAD software (e.g., SolidWorks) is a plus


• Ability to travel occasionally to supplier sites (up to 10%)

Preferred Qualifications

• Strong problem‑solving and analytical skills


• Interest in root cause analysis and continuous improvement techniques


• Effective teamwork and communication skills


• Ability to manage multiple tasks in a fast‑paced, deadline‑driven environment


• Demonstrates initiative and responsibility for assigned work


• Commitment to learning and professional growth

Physical Demands

• Ability to work in an office environment (constant)


• Required to sit or stand for extended periods and use computer and office equipment frequently

Clearance Level

No Clearance

The salary range for this role is:

AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s work experience, education/training, and key skills.

ITAR Requirement:

This position requires access to information that is subject to compliance with the International Traffic Arms Regulations ("ITAR") and/or the Export Administration Regulations ("EAR"). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A "U.S. person" according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements.

Benefits: AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown. For more information about our company benefit offerings please visit: http://www.avinc.com/myavbenefits

We also encourage you to review our company website at http://www.avinc.com to learn more about us.

Principals only need apply. NO agencies please.

About AV:

AV isn't for everyone. We hire the curious, the relentless, the mission‑obsessed. The best of the best.

We don't just build defense technology - we redefine what's possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve.

Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian - we're not building history, we're building what's next.

If you're ready to build technology that matters - with speed, scale, and purpose - there's no better place to do it than AV.

We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status.

ITAR

U.S. Citizen, U.S. Permanent Resident (Green Card holder), asylee/refugee status as defined by 8 U.S.C. 1324b(a)(3) or a person approved for an export license from the appropriate governing agency.