Mechanical Prototyping Engineer

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