Intern – Materials Engineering

Intern - Materials Engineering

Focus: Materials research, characterization, and process-structure-property analysis for metal-ceramic matrix surface architectures

Location: West Lafayette, IN (HARF)

Duration: TBD

Work Authorization / Clearance: U.S. Citizen; must be U.S. clearance eligible

Preferred: Active security clearance

Organization: Advanced manufacturing startup supporting military and commercial programs

Role Summary

INTALUS is seeking a Materials Engineering Summer Intern to support materials R&D, measurement workflows, and characterization for metal-ceramic matrix surface architectures produced on INTALUS directed-energy, multi-axis robotic platforms. This role is measurement- and analysis-facing: specimen handling, microstructural evaluation, metrology, data reduction, and repeatable documentation. The intern will work in close coordination with Manufacturing Engineering personnel who execute machine-side processing.

Key Responsibilities

1. Materials characterization and measurement workflows

• Prepare and track specimens through the measurement pipeline (labeling, travelers, chain-of-custody, storage).
• Support metallography workflows (sectioning, mounting, grinding/polishing, etching as applicable).
• Perform and document characterization tasks (as available): optical microscopy, SEM sample prep/support, hardness testing, surface roughness measurement, dimensional metrology, and infused-zone depth/feature measurements where applicable.
• Compile and curate structured datasets tying run IDs and conditions to measured outputs.

2. Process-structure-property analysis

• Help analyze relationships between processing conditions and resulting microstructure/properties (trend analysis, repeatability checks, anomaly detection).
• Support DOE-style trial planning (measurement plans, controls, repeat runs, and data quality checks).
• Produce concise technical summaries suitable for engineering review (tables, plots, standardized reporting templates).

3. Quality system support (AS9100 / ISO 9001 readiness)

• Draft and improve controlled documentation for measurement and lab workflows: SOPs, checklists, inspection steps, acceptance criteria, and record templates.
• Support traceability and record completeness for materials lots, specimens, and measurement outcomes (objective evidence discipline).
• Assist with calibration/verification records for measurement tools and fixtures.

4. CMMC-aligned engineering data practices (Level 1-2)

• Support inventory of where technical data is generated/stored/shared for materials measurements and reports.
• Help develop checklists and short training aids for engineering cyber hygiene (controlled files, access control expectations, secure transfer habits).

5. Lab safety and operations support

• Maintain lab notebooks, equipment readiness checklists, and consumables tracking.
• Follow safety procedures for sample prep tools, chemicals, and lab equipment.

What You'll Gain

• Hands-on experience with materials characterization workflows applied to defense- and aerospace-relevant manufacturing.
• Practical exposure to process-structure-property analysis and disciplined experimental documentation.
• Experience building traceable measurement records and controlled lab artifacts aligned to AS9100 / ISO 9001 expectations.
• Close collaboration with a startup engineering team in the Purdue Innovation Ecosystem.