Summer Research Program Intern 2027, Fabrication Engineering Integration (Group 07-72)

Location: Lexington, MA, US

The Fabrication Engineering Group provides rapid fabrication, assembly, integration, and test of advanced hardware prototypes for national security applications.  Examples include the precision machining of fiber mounts for airborne high energy laser systems, multi-functional structures using additive processes for ground-based radar systems, custom printed circuit boards (PCBs) for space-borne data processing, and highly integrated mechanical packaging for undersea communication terminals. Core mechanical competencies span precision fabrication, additive manufacturing, and 5-axis machining. The group concentrates on high-complexity parts, quick-turn capabilities and activities that require concurrent engineering with program teams.  Core PCB capabilities include design for manufacturability (DFM), automated solder paste dispensers, precise pick-n-place machines, and automated optical inspection systems.  Assembly, integration, and test capabilities include integration spaces, clean rooms, vibration testing, thermal testing, and space simulation chambers.  The Group focuses on state-of-practice prototyping capabilities, technical excellence, exceptional collaboration and outstanding operation.

Position Description

The Fabrication Engineering Division seeks a summer intern to support the integration, assembly, test, and documentation of complex prototype hardware systems. The intern will work under the guidance of fabrication engineers, technicians, designers, and project teams to help translate engineering designs into assembled prototype hardware.

The position is intended for students interested in hands-on engineering, mechanical and electromechanical systems, prototype fabrication, test operations, manufacturing processes, and systems integration. Assignments may involve components or subsystems with mechanical, electrical, pneumatic, fluid, optical, instrumentation, or control-system interfaces, depending on program needs and the intern’s qualifications.

Primary Responsibilities

The intern may perform the following activities under appropriate supervision and in accordance with established work controls:

Support assembly and integration of prototype hardware, fixtures, test articles, and engineering subsystems.

Assist with interpreting engineering drawings, bills of materials, work instructions, assembly procedures, and interface-control documentation.

Help prepare components, tools, fixtures, and work areas for fabrication, assembly, inspection, or testing.

Participate in fit checks, tolerance verification, alignment activities, and functional checkout of hardware assemblies.

Assist engineers and technicians in identifying mechanical, electrical, or system-interface issues during integration activities.

Document assembly steps, configuration changes, test observations, discrepancies, and corrective actions.

Support the development or revision of work instructions, travelers, build records, test procedures, and as-built documentation.

Help maintain configuration control of hardware, parts, tooling, and associated technical documentation.

Assist with data collection during prototype tests, including recording measurements, observations, photographs, and instrumentation outputs as authorized.

Support root-cause investigations and troubleshooting efforts by organizing test data, documenting conditions, and participating in structured problem-solving activities.

Participate in engineering design reviews, daily work planning, safety briefings, and technical meetings.

Perform basic shop, laboratory, and equipment support tasks within the intern’s training, authorization, and supervision level.

Preferred Focus Areas

Preference may be given to candidates with demonstrated interest or experience in:

Complex mechanical, electromechanical, or mechatronic hardware systems

Prototype assembly and integration

Test fixtures, experimental hardware, or laboratory equipment

Precision fabrication, machining, welding, additive manufacturing, or composite systems

Instrumentation, sensors, data acquisition, or control systems

Mechanical design, CAD modeling, and engineering drawing interpretation

Manufacturing engineering, quality assurance, inspection, and configuration management

Systems engineering and interface management

Learning Opportunities

The intern will have the opportunity to

Gain direct experience with engineering hardware development from design release through assembly and test.

Learn how multidisciplinary teams manage interfaces, configuration, quality, safety, and schedule during prototype development.

Build practical skills in technical documentation, measurement, troubleshooting, and structured problem solving.

Observe or support fabrication processes, prototype testing, and engineering design reviews.

Receive mentorship from experienced engineers, technicians, machinists, and project personnel.

Qualifications

Required Qualifications

Current enrollment in an accredited undergraduate or graduate program in mechanical engineering, manufacturing engineering, aerospace engineering, electrical engineering, systems engineering, industrial engineering, engineering technology, physics, or a related technical discipline.

Completion of at least one year of post-secondary education by the start of the internship.

Demonstrated interest in hands-on engineering, fabrication, laboratory work, or prototype development.

Ability to follow detailed procedures, work instructions, drawings, and safety requirements.

Basic familiarity with engineering tools, measurement methods, laboratory practices, or fabrication processes.

Ability to work effectively in a team environment with engineers, technicians, machinists, and other technical personnel.

Strong attention to detail, organizational skills, and written communication skills.

Ability to maintain accurate records and handle technical information responsibly.

Desired Qualifications

Ex