Mechanical Engineering Intern – Advanced Stealth AI Hearables

Work Authorization: U.S. Citizen or Green Card Holder

Mechanical Engineering Intern – Advanced Stealth AI Hearables

Location: Rockville, MD (On-site only)

Employment Type: Part-Time or Full-Time Internship          

Education: Pursuing or recently graduated with a Bachelor’s, Master’s, or Ph.D. degree in Mechanical Engineering, Industrial Design, Acoustical Engineering, or a related field

GPA: 2.5+

Function: Engineering / Mechanical Design / Product R&D

Industry: Defense / Wearables / AI

About the Role

Unheard, Unseen, Unstoppable. Just as Meta’s Ray-Bans and Apple’s AirPods revolutionized the commercial hearable space, Stacato is leading the next frontier of communications for the world’s elite operators with stealth wireless hearables built to integrate next-gen AI capabilities.

We’re seeking a Mechanical Engineering Intern who’s excited to take part in the design and hands-on development of high-performance wearable hardware. You’ll contribute directly to the creation and refinement of compact, ruggedized assemblies and next-generation prototypes for our advanced communications line.

What You’ll Do

- Assist in mechanical design and prototyping of small, precision-engineered components for wearables

- Build and test your own prototype ideas: Explore ways to improve ergonomics, assembly, and durability

- Create and refine CAD models and drawings (SolidWorks, Fusion 360, or equivalent)

- Participate in fit, form, and function testing

- Support rapid prototyping using 3D printing, machining, and hands-on fabrication tools

What You Bring

- Pursuing or recently graduated with a Bachelor’s, Master’s, or Ph.D. in Mechanical Engineering, Industrial Design, Acoustical Engineering, or a related field

- Experience and interest in hands-on prototyping, fabrication, or product assembly

- Comfortable using shop tools, 3D printers, and basic machining or hand-fabrication techniques 

- Familiarity with CAD modeling (SolidWorks, Fusion 360, or similar)

- Curiosity about miniaturized mechanical design: How to make small parts strong, ergonomic, and manufacturable

- Understanding of materials, tolerance stack-ups, and mechanical testing principles (acoustics knowledge is a plus!)

- Self-starter with a builder’s mindset: You don’t just design ideas, you make them real

Why Join Stacato?

At Stacato, you'll engineer advanced tactical hearables designed for real-world use by elite operators. This is purposeful, high-stakes work at the intersection of audio, wearables, and AI, working alongside a focused, high-performing team. Exceptional interns may be considered for future opportunities with the company.

*Please also send your cover letter to jobs@stacato.com