Manufacturing Engineering Intern - Spring 2027

About Thea Energy:

Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.

Key Responsibility Areas: • Assist in generating and updating test documentation, including standard operating procedures (SOPs), work instructions, and quality criteria for HTS magnet testing. • Support design, prototyping, and commissioning of custom test fixtures and equipment. • Work alongside test engineers, magnet designers, and manufacturing engineers to incorporate "lessons learned" from testing into future designs. • Manage virtual and physical inventory, organize assembly areas, and update manufacturing Bills of Materials (BOMs). • Assist hardware procurement, evaluating vendor specs, and ensuring incoming parts meet quality standards. • Track test metrics and results, and progress against critical program milestones.

Ideal Experience & Skillsets:

• Currently pursuing a Bachelor’s, Master’s or PhD in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related technical field. • Strong foundational understanding of engineering drawings and spatial mechanics (exposure to GD&T is a major plus). • Hands-on project experience (e.g., Formula SAE, rocketry club, robotics club, etc.) involving mechanical or electrical hardware design, build, and test. • Familiarity with relevant hardware and software for developing test controls including LabView, Python, National Instruments, thermocouples and voltage taps, and similar equipment and software • Direct experience with fabrication or assembly processes such as machining (hand tools, manual mill, CNC), fastened and bonded assemblies, soldering, etc. • Familiarity with CAD software (e.g., SolidWorks, NX). • Ability to work through and solve highly multidisciplinary engineering problems • Ability to take initiative, work independently and as part of a team • Exceptional work ethic, with clear communication and collaboration skills • Ability to occasionally lift objects up to 50 lbs.

Company Benefits:

• Salary range $21 - $25/hour

Requirements:

• Ability to occasionally lift up to 50 lbs.

• Ability to perform activities such as typing, standing, or sitting for extended periods of time.

• Ability to work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, high voltage, high current, pressure systems, and cryogenics.

Key Responsibilities:

• Assist in generating and updating manufacturing documentation, including standard operating procedures (SOPs), work instructions, and quality criteria for HTS magnet assembly.

• Support design, prototyping, and commissioning of custom manufacturing tooling, fixtures, and equipment.

• Work alongside magnet designers and manufacturing engineers to incorporate "lessons learned" from the shop floor into future designs.

• Manage virtual and physical inventory, organize assembly areas, and update manufacturing Bills of Materials (BOMs).

• Assist hardware procurement, evaluating vendor specs, and ensuring incoming parts meet quality standards.

• Track production metrics, test results, and progress against critical program milestones.