Mechanical Engineering Intern

Ultrasonium; Woburn (MA); On-site; USD 27,552 - 55,104; Full time

Benefits offered by this job

Mentorship from founding team

Flexible scheduling

Hands-on hardware experience

NSF-funded research involvement

Job summary

Ultrasonium is seeking a student in Mechanical, Electrical, or Materials Science to design mechanical components and assemblies for metal additive manufacturing systems. You will work with our engineering team from whiteboard sketches through prototyping and testing, gaining exposure to the full hardware development cycle at a fast-moving startup.

You will CAD in Fusion 360, build prototypes, run real-world tests, perform failure analysis, and collaborate with sensors and control hardware teams.

Qualifications

• Currently enrolled in a Bachelor’s or Master’s program in Mechanical Engineering, Electrical Engineering, Materials Science, or a closely related field.
• Proficiency with 3D CAD software.
• Hands-on prototyping experience - you have built real hardware and are comfortable with tools and lab equipment.
• Strong attention to detail with a safety-conscious mindset, particularly around high-temperature systems.

Responsibilities

• Design mechanical components and assemblies for metal additive manufacturing systems, with an emphasis on high-temperature and high-load conditions.
• Create detailed CAD models, drawings, and supporting mechanical documentation using Fusion 360 or equivalent software.
• Build and assemble functional prototypes using rapid prototyping techniques, machining, and off-the-shelf hardware.
• Conduct mechanical testing under real operating conditions; collect data, analyze results, and document findings.
• Perform failure analysis on prototype components and iterate designs to address identified weaknesses.
• Collaborate with electrical and robotics engineers to ensure mechanical designs integrate cleanly with sensors, actuators, and control hardware.
• Support the development of assembly SOPs and test procedures as the system matures toward pilot-scale operation.

Skills

Prototyping

CAD proficiency

Attention to detail

Team collaboration

Safety awareness

Education

Bachelors or Masters in Mechanical Engineering, Electrical Engineering, or Materials Science

Tools

Fusion 360

Lab equipment

Job description

This role is centered on developing structures, mechanisms, and assemblies that must perform reliably in high-temperature, high-power environments. You will work shoulder-to-shoulder with our engineering team, from whiteboard sketches through prototyping and physical testing, and gain rare exposure to the full hardware development cycle at a fast-moving startup.

You might be a great fit if you...

• Want to help reduce energy use in manufacturing.
• Are comfortable with ambiguity. Our system is novel; there are no textbooks with the answers. Creative, cross-disciplinary thinking is essential.
• Want to see your work matter quickly. In a lean startup, your contributions go directly into the machine.
• Are genuinely curious about advanced manufacturing and materials science.
• Thrive in a collaborative, fast-paced environment and communicate clearly across technical disciplines.

Key responsibilities

• Design mechanical components and assemblies for metal additive manufacturing systems, with an emphasis on high-temperature and high-load conditions.
• Create detailed CAD models, drawings, and supporting mechanical documentation using Fusion 360 or equivalent software.
• Build and assemble functional prototypes using rapid prototyping techniques, machining, and off-the-shelf hardware.
• Conduct mechanical testing under real operating conditions; collect data, analyze results, and document findings.
• Perform failure analysis on prototype components and iterate designs to address identified weaknesses.
• Collaborate with electrical and robotics engineers to ensure mechanical designs integrate cleanly with sensors, actuators, and control hardware.
• Support the development of assembly SOPs and test procedures as the system matures toward pilot-scale operation.

Required qualifications

• Currently enrolled in a Bachelor's or Master's program in Mechanical Engineering, Electrical Engineering, Materials Science, or a closely related field.
• Proficiency with 3D CAD software.
• Hands-on prototyping experience - you have built real hardware and are comfortable with tools and lab equipment.
• Strong attention to detail with a safety-conscious mindset, particularly around high-temperature systems.

Preferred qualifications

• Coursework or project experience in heat transfer, fluid mechanics, manufacturing processes, or materials selection.
• Familiarity with GD&T, tolerance analysis, or design for manufacturability (DFM) principles.
• Experience with FEA tools (e.g., COMSOL, Ansys, or Fusion 360 Simulation) for structural or thermal analysis.
• Prior internship, research lab, or maker-space experience in a hardware-focused environment.
• Any exposure to additive manufacturing or high-temperature processing is a plus, but not required.

What we offer

• Hands-on experience at the frontier of metal additive manufacturing.
• Direct mentorship from the founding engineering team.
• A lean, collaborative environment where your ideas are heard and acted upon quickly.
• Flexible scheduling to accommodate academic commitments; full-time or part-time arrangements considered.
• The opportunity to contribute to NSF-funded research with real-world industrial applications.