Mechanical Prototyping Engineer (MS or PhD Student) – ORNL Intern
Cassette Construction is seeking a graduate student intern (MS or PhD) through ORNL to help build and validate a prototype programmable die for our extrusion-based manufacturing system. This is a hands-on role combining mechanical design, fabrication, electromechanical assembly, controls integration, and rigorous testing and documentation.
Responsibilities
- Build and iterate a programmable die prototype, including:
- Mechanical assembly, fit-up, alignment, and troubleshooting
- Wiring and basic electrical integration (connectors, cable management, strain relief, continuity checks)
- Programming, instrumentation, and data-logging
- Mechanical design and iteration:
- 3D modeling and design updates
- Drawing generation, detailing, and revision control
- Design-for-manufacture and design-for-assembly improvements
- Documentation and testing:
- Develop build notes, test plans, and procedures
- Execute experiments, collect data, and summarize results clearly
- Maintain organized records and communicate progress/issues promptly
- Collaborate with the broader team to scope tasks, plan work, and resolve technical blockers
Required qualifications
- Current MS or PhD student in Mechanical Engineering (or closely related field)
- Demonstrated fabrication experience (shop work, prototyping, assembling mechanisms)
- Proficiency with general shop tools and safe work practices (hand tools, drill press, saws, basic fixturing/metrology)
- Experience with 3D CAD and drawings (e.g., SolidWorks, Inventor, or similar)
- Ability to work independently: planning tasks, executing without step-by-step oversight, and delivering reliable outputs
- Strong attention to detail in research/workflows; able to document work cleanly and consistently
- Critical thinking and practical problem-solving (debugging mechanical/electrical integration issues)
Preferred qualifications
- Experience with mechatronics, actuators and sensors, microcontrollers, or motion/control systems
- Comfort with rapid iteration: prototyping, testing, redesigning, and re-building
- Familiarity with structured test methods and basic data analysis
Working style expectations
- Respectful, collaborative, and communicates clearly
- Asks questions early, flags risks, and proposes solutions
- Organized, dependable, and careful with shared tools and equipment