Mechanical Engineer Intern (Summer 2027)

Beyond Reach Labs; New York (NY); On-site; USD 80,000 - 120,000; Full time

Job summary

Beyond Reach Labs is seeking a Mechanical Engineer to design, analyze, and validate mechanical systems and actuators for deployable space structures. You will shape the next generation and improve existing mechanisms for reliability and manufacturability.

Responsibilities include CAD modeling, conducting FEA under static/dynamic/thermal loads, and executing test plans. You’ll collaborate with cross-functional teams to ensure seamless integration with spacecraft and meet project milestones.

Qualifications

• Designing and qualifying mechanisms driven by motors, springs, and HDRMs.
• Ability to create CAD models and drawings for production and analysis.
• Experience with mechanism design trade studies and First Principles Engineering Analysis.

Responsibilities

• Identify requirements, perform trade studies, and apply First Principles Engineering Analysis to optimize mechanisms.
• Create and iterate CAD models, mechanism architecture, materials, assembly processes, and test methods.
• Run classical and FEA analyses for static, dynamic, thermal, and fatigue loads to ensure margins.

Skills

CAD software

First Principles Analysis

FEA analysis

Stepper/BLDC mechanisms

Project management

Education

Bachelor’s degree in Mechanical/Aerospace Engineering or related field

Tools

Fusion 360

Ansys

Job description

They say the best deployable is no deployable, but we believe large deployable mechanisms are the future for large infrastructure in space.

At Beyond Reach Labs, we are designing and building the largest deployable structures ever flown to space. As an engineering-driven organization, you will be at the forefront of the company's key technology development.

To make this possible, mechanical systems will need to be greatly simplified, more reliable, and easier to manufacture. As a Mechanical Engineer, you will be responsible for designing, analyzing, and validating mechanical systems and actuators for our deployable structures. These mechanisms are used in various applications from solar arrays to radiators. You will be entrusted to improve existing systems while also helping to shape and design the next generation.

Key Responsibilities:

• Design and Development:

  • Identify and analyze requirements, conduct trade studies on mechanism design options, and apply First Principles Engineering Analysis to optimize mechanisms and systems for satellites.

  • Create and iterate detailed CAD models, including mechanism architecture, material/lubrication selections, assembly processes, and test methods.

  • Conduct classical and FEA analysis for all load conditions (static, dynamic, thermal, fatigue) to ensure adequate margins and reliability.

• Testing and Validation:

  • Develop and execute comprehensive test plans throughout development.

  • Define qualification plans and identify acceptance testing methods.

  • Produce complete design packages, including detailed drawings, analysis reports, BOMs, and assembly documentation.

• Optimization and Cost Management:

  • Facilitate cost trades on multiple parallel configurations to balance cost, manufacturability, and design risk.

  • Collaborate with cross-functional teams and customers to ensure smooth integration with the spacecraft.

Basic Qualifications:

• Working towards a Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field.

• 6+ months of experience outside the classroom

  • Project Teams

  • Research

  • Internships

• Experience designing and qualifying mechanisms driven by stepper or BLDC motors, springs, and HDRMs.

• Proficient in developing design models and drawings for production and analysis using CAD software.

Preferred Qualifications:

• Project management experience for technical projects.

• Expertise in materials selection for space applications.

• Experience working with very large lightweight deployable structures

• Proficiency using Fusion and Ansys for CAD and analysis.

Additional Requirements:

• Minimum 12 weeks on-site

• Willingness to work extended hours and weekends as necessary to support critical project milestones.

• Must be a U.S. citizen, lawful permanent resident, or eligible for authorization under U.S. export regulations.

Beyond Reach Labs is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, gender, national origin, age, disability, veteran status, sexual orientation, gender identity, or any other characteristic protected by applicable law.