Manufacturing Engineering Intern - Spring 2027

U.S. Fusion Energy; Illinois; On-site; USD 29,000 - 34,000; Full time

Benefits offered by this job

Salary range $21 - $25/hour

Job summary

Thea Energy is offering a Spring 2027 Manufacturing Engineering Intern position in Kearny, NJ. This on-site role supports test engineering, design, prototyping, and shop-floor manufacturing activities, working with magnet designers and manufacturing engineers to implement lessons learned from testing into future builds.

The internship seeks students in Mechanical/Aerospace/Materials with hands-on project experience and familiarity with LabView, Python, CAD tools, and fabrication processes.

Job description

Manufacturing Engineering Intern - Spring 2027

Kearny, NJ

Internships – Test Engineering / Internship / On-site

About Thea Energy

Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.

Key Responsibility Areas

• Assist in generating and updating test documentation, including standard operating procedures (SOPs), work instructions, and quality criteria for HTS magnet testing.
• Support design, prototyping, and commissioning of custom test fixtures and equipment.
• Work alongside test engineers, magnet designers, and manufacturing engineers to incorporate "lessons learned" from testing into future designs.
• Manage virtual and physical inventory, organize assembly areas, and update manufacturing Bills of Materials (BOMs).
• Assist hardware procurement, evaluating vendor specs, and ensuring incoming parts meet quality standards.
• Track test metrics and results, and progress against critical program milestones.

Ideal Experience & Skillsets

• Currently pursuing a Bachelor’s, Master’s or PhD in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related technical field.
• Strong foundational understanding of engineering drawings and spatial mechanics (exposure to GD&T is a major plus).
• Hands‑on project experience (e.g., Formula SAE, rocketry club, robotics club, etc.) involving mechanical or electrical hardware design, build, and test.
• Familiarity with relevant hardware and software for developing test controls including LabView, Python, National Instruments, thermocouples and voltage taps, and similar equipment and software
• Direct experience with fabrication or assembly processes such as machining (hand tools, manual mill, CNC), fastened and bonded assemblies, soldering, etc.
• Familiarity with CAD software (e.g., SolidWorks, NX).
• Ability to work through and solve highly multidisciplinary engineering problems
• Ability to take initiative, work independently and as part of a team
• Exceptional work ethic, with clear communication and collaboration skills
• Ability to occasionally lift objects up to 50 lbs.

Company Benefits

• Salary range $21 - $25/hour

Requirements

• Ability to occasionally lift up to 50 lbs.
• Ability to perform activities such as typing, standing, or sitting for extended periods of time.
• Ability to work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, high voltage, high current, pressure systems, and cryogenics.

Key Responsibilities

• Assist in generating and updating manufacturing documentation, including standard operating procedures (SOPs), work instructions, and quality criteria for HTS magnet assembly.
• Support design, prototyping, and commissioning of custom manufacturing tooling, fixtures, and equipment.
• Work alongside magnet designers and manufacturing engineers to incorporate "lessons learned" from the shop floor into future designs.
• Manage virtual and physical inventory, organize assembly areas, and update manufacturing Bills of Materials (BOMs).
• Assist hardware procurement, evaluating vendor specs, and ensuring incoming parts meet quality standards.
• Track production metrics, test results, and progress against critical program milestones.

It’s not necessary to meet all of the skillsets outlined above. Please feel free to send us a note and tell us why you would still be a great fit for this role or Thea Energy.

Diversity And Inclusion

Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. By creating a diverse environment, we will bring new ideas and approaches to solving some of the world’s hardest (and most important) problems. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran’s status, or other characteristic protected by applicable laws and regulations.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.