Mechanical Design Engineering Internship

Internship Duration:

May 2026 - August 2026

Role Summary

Amperesand is working to develop, build, test, and validate a ground-up redesigned next-generation solid state transformer (SST) and the power stage modules (PSMs) that convert power from medium-voltage AC to customer-facing DC output. This internship will include building and testing of prototype units, root cause analysis of issues found, and design and changes of parts to fix or improve.

Responsibilities:

• Utilize CAD software to create detailed mechanical designs. 3DX/Catia experience preferred but not required.
• Model and design complex electro-mechanical parts, including plastics, sheet metal, insulators, magnetic components, and high-voltage connectors.
• Perform mechanical design analysis by means of first principal calculation or simulation with commercial software, including structural FEA, thermal CFD, vibration, and fatigue assessments.
• Solve packaging challenges involving electrical isolation, sealing, thermal dissipation, EMI/EMC shielding, and mechanical shock/vibration.
• Perform prototype development, fabrication, assembly, and mechanical testing of new designs.
• Support root-cause analysis of design issues in pilot or production builds and lead iterative improvements.
• Define and execute validation test plans including structural, thermal, and environmental testing.
• 2D drawings with GD&T for production and inspection.
• Create engineering documentation, tolerance stacks, BOMs, and release packages through PLM systems.
• Collaborate cross-functionally with electrical, thermal, firmware and controls, manufacturing, test, and industrial design teams.
• Work closely with suppliers to optimize DFM, DFA, and tooling strategies for high-volume production.

Qualifications:

• Final year undergraduate standing or graduate study in Mechanical Engineering or a closely-related field.
• Expertise in CAD modeling using 3D EXPERIENCE (CATIA V6/V5), SolidWorks, NX, or Creo.
• Deep understanding of mechanical fundamentals - statics, dynamics, heat transfer, and materials.
• Working knowledge of materials: metals (aluminum, steel), plastics, ceramics, gaskets, potting compounds.
• Comfortable with root-cause analysis, failure mode resolution, and mechanical reliability testing.
• Passion for product innovation, sustainability, and enabling electrification through engineering excellence.

Bonus Qualifications:

• Strong background in structural, thermal, and vibration analysis using commercial software, e.g. Ansys.
• Proficiency in GD&T, tolerance analysis, and DFM/DFA principles.
• Familiarity with PCBAs, connectors, and mechanical integration of high-density electronic assemblies.
• Experience with high-volume manufacturing processes such as injection molding, die casting, extrusion, and sheet metal forming.
• Experience with medium- to high-voltage systems and insulation coordination (creepage, clearance, potting, sealing).
• Experience working in Agile development environments, including task management and sprint planning using Scrum methodologies and tools like Jira.

Please note:

This role requires working on-site 5 days a week. We do not offer hybrid or remote options.

Compensation:

$30 - $45/hour depending on location and level of experience