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Mechanical Engineering Intern — Key Responsibilities and Required Skills

💰 $18 - $32 / hour

Mechanical EngineeringInternshipEngineering

🎯 Role Definition

The Mechanical Engineering Intern supports engineering teams by assisting with product design, prototyping, testing, and documentation. This entry-level role translates conceptual requirements into CAD models and physical prototypes, executes lab and field tests, analyzes results, and helps drive continuous improvement in design and manufacturing. The intern works under supervision across R&D, product development, manufacturing engineering, and quality teams to gain hands-on experience with real-world engineering problems and tools.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Undergraduate student in Mechanical Engineering or related discipline
  • Recent graduate with capstone/project experience in product design or prototyping
  • Technical co-op, CAD technician, or machine shop apprentice

Advancement To:

  • Mechanical Engineer I / Junior Mechanical Engineer
  • Test Engineer / Validation Engineer
  • Manufacturing Engineer / Process Improvement Engineer

Lateral Moves:

  • CAD/CAE Specialist
  • Quality Engineer (entry-level)
  • R&D Technician / Prototype Technician

Core Responsibilities

Primary Functions

  • Develop and modify 3D CAD models and 2D detailed drawings using SolidWorks, Creo, CATIA, or AutoCAD to support product development, design reviews, and manufacturing release while ensuring proper tolerances and fitments.
  • Support prototype build activities by preparing bill of materials (BOMs), creating fabrication and assembly instructions, selecting materials and parts, and coordinating with machine shop or vendors to ensure timely delivery of prototype components.
  • Assist senior engineers in executing lab and bench tests, including setup of test rigs, instrumentation (strain gauges, thermocouples, load cells), data acquisition (DAQ), and conducting controlled experiments to validate design performance.
  • Collect, preprocess, and analyze test data (time-series, force/torque, displacement, temperature) using Excel, MATLAB, or Python; generate plots, summary statistics, and concise technical observations for engineering reviews.
  • Perform basic finite element analysis (FEA) and hand calculations under supervision to evaluate stresses, deflections, heat transfer, or modal behavior; document boundary conditions, assumptions, and sensitivity checks.
  • Prepare and maintain clear engineering documentation: test plans, test reports, design change requests (ECR/ECO), engineering notebooks, and standard operating procedures (SOPs) compliant with company processes and engineering standards.
  • Participate in formal design reviews (DFMEA, peer reviews) by presenting CAD models, test findings, and proposed design changes; incorporate reviewer feedback and update models and drawings accordingly.
  • Support tolerance analysis and stack-up studies to ensure manufacturability and assembly function; recommend geometric dimensioning and tolerancing (GD&T) that balance cost and performance.
  • Collaborate with manufacturing and supply chain teams to transition prototypes to production: recommend process steps, tooling needs, CNC programs, assembly fixtures, and quality checkpoints.
  • Assist with root cause analysis for product failures and field issues by participating in failure mode investigations, collecting evidence, performing reproducible lab tests, and documenting corrective action proposals.
  • Evaluate alternative materials, fasteners, adhesives, and surface treatments to meet performance, cost, and regulatory requirements; support material selection for weight reduction, durability, and manufacturability.
  • Support electronics and mechanical integration tasks by coordinating with electrical engineers to mount PCBs, route harnesses, and ensure thermal and mechanical compatibility of multi-disciplinary assemblies.
  • Fabricate and assemble experimental prototypes using hand tools, light machining, sheet metal bending, 3D printing, and adhesives while adhering to shop safety standards and documentation requirements.
  • Contribute to continuous improvement initiatives by proposing design changes, updating assembly instructions, and helping drive Kaizen projects to reduce cycle time or scrap in manufacturing processes.
  • Maintain and calibrate lab and test equipment, track inventory of consumables and tooling, and ensure safety protocols, PPE use, and machine guarding guidelines are followed in testing and fabrication areas.
  • Support regulatory and compliance activities by helping gather technical data, test results, and documentation for CE, UL, RoHS, REACH, or industry-specific standards under direction of senior engineers.
  • Create and update models for tolerance stack-ups, cost modeling, and manufacturability reviews to help prioritize engineering work and support early cost-estimation efforts.
  • Assist in benchmarking competitor products by disassembling parts, measuring geometries, identifying materials and manufacturing processes, and summarizing findings to inform design decisions.
  • Work with suppliers to source components and specialty materials, obtain quotes, review supplier drawings, and help evaluate vendor capability against engineering requirements.
  • Participate in cross-functional project teams (marketing, operations, quality, procurement) to ensure product requirements, timing, and manufacturing constraints are communicated and met during development cycles.
  • Support software/hardware integration testing where mechanical function interacts with firmware or control systems, executing test scripts and documenting any mechanical-related anomalies.
  • Prepare clear, SEO-optimized technical summaries and presentation slides for weekly project updates, senior engineering reviews, and manager briefings that highlight test outcomes, risks, and next steps.

Secondary Functions

  • Shadow senior engineers during field testing and customer site visits to support installation validation, on-site measurement, and troubleshooting.
  • Assist with lifecycle and reliability testing programs (thermal cycling, vibration, humidity) by preparing specimens, labeling samples, and logging test progress and anomalies.
  • Support sustainability and material reuse initiatives by documenting material sources, recyclability, and potential design modifications to reduce environmental impact.
  • Help maintain engineering databases, CAD libraries, standard parts, and version control practices to promote reuse and reduce design time on repeated components.
  • Support quick-turn engineering change implementations, including updating drawings, communicating changes to manufacturing, and verifying the first article build.
  • Produce annotated photographs, exploded assembly images, and diagrams for assembly manuals, service guides, and part catalogs to aid manufacturing and aftermarket teams.
  • Participate in internship programs, technical training sessions, and knowledge sharing presentations to grow engineering skills and mentor newer interns or technicians.

Required Skills & Competencies

Hard Skills (Technical)

  • Proficiency in 3D CAD modeling and detailing (SolidWorks, Creo, CATIA, or AutoCAD) with experience producing production-ready drawings and BOMs.
  • Familiarity with finite element analysis (ANSYS, Abaqus, SolidWorks Simulation) or hands-on support for CAE workflows and validation.
  • Basic scripting and data analysis skills in MATLAB, Python (pandas, numpy), or Excel (advanced functions, pivot tables) for processing test and simulation data.
  • Working knowledge of GD&T (ASME Y14.5) and tolerance analysis for manufacturability and assembly fit.
  • Hands-on prototyping experience: 3D printing (FDM/SLA), CNC machining basics, sheet metal processes, adhesives, and assembly techniques.
  • Practical understanding of manufacturing processes: injection molding, stamping, casting, machining, assembly line operations and design-for-manufacturability (DFM) principles.
  • Experience with test equipment and measurement tools: calipers, micrometers, dial indicators, strain gauges, thermocouples, oscilloscopes, and DAQ systems.
  • Ability to author technical documents: test plans, test reports, SOPs, CAD release packages, and engineering change notices.
  • Familiarity with materials science fundamentals (metals, plastics, composites) and material property selection for mechanical performance and durability.
  • Knowledge of product lifecycle management (PLM) or version control tools and document control best practices (e.g., PDM/PLM systems, Git for code/scripts).
  • Exposure to reliability and environmental testing protocols (thermal cycling, vibration, shock, IP testing) is a plus.
  • Basic electrical integration awareness and the ability to collaborate with electronics engineers on packaging, connectors, and thermal interfaces.

Soft Skills

  • Strong verbal and written communication: concise test summaries, clear CAD annotations, and professional presentation skills for cross-functional stakeholders.
  • Critical thinking and structured problem solving with attention to root cause and corrective action.
  • Collaborative team player who can work effectively with R&D, manufacturing, quality, and supply chain teams.
  • Time management and prioritization: able to handle multiple tasks, meet deadlines, and escalate risks proactively.
  • Adaptability and continuous learning mindset to pick up new tools, processes, and manufacturing techniques quickly.
  • Attention to detail and accuracy in measurements, documentation, and drawing release procedures.
  • Initiative and ownership: comfortable driving assigned tasks to completion and asking clarifying questions when scope is unclear.
  • Safety-conscious attitude with commitment to laboratory and shop safety protocols and PPE usage.

Education & Experience

Educational Background

Minimum Education:

  • Currently enrolled in or recently completed a Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Mechatronics, or closely related field.

Preferred Education:

  • Progress toward or completion of an advanced degree (Master’s) in Mechanical Engineering, or specialization in design/controls/manufacturing.
  • Coursework or certificate in CAD, FEA, materials, or manufacturing processes.

Relevant Fields of Study:

  • Mechanical Engineering
  • Aerospace Engineering
  • Mechatronics / Robotics
  • Materials Science and Engineering
  • Industrial Engineering (manufacturing emphasis)
  • Applied Physics (with mechanical focus)

Experience Requirements

Typical Experience Range: 0–2 years (academic projects, capstone design, co-ops, prior internships)

Preferred:

  • 1 or more internships/co-op rotations in mechanical design, prototype development, test engineering, or manufacturing support.
  • Demonstrated project work (senior capstone, lab projects) that includes CAD models, prototype builds, testing, and technical reporting.
  • Familiarity with industry-standard tools (SolidWorks, MATLAB, ANSYS, LabVIEW) and exposure to shop environments and safe machining practices.
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