Manufacturing Engineering Intern - Fall 2026

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.

• Currently pursuing a Bachelor’s or Master’s degree 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.

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.