Internship Dod Mechanical Engineer Jobs (NOW HIRING)

Job Title

Mechanical Engineer

Job Description

This role focuses on supporting the design, analysis, and sustainment of fielded unmanned aircraft systems (UAS) and associated ground launch systems. You will contribute to engineering analyses, integration of new components, and testing activities for air vehicles and launch systems, while preparing technical documentation and collaborating with cross-functional teams to ensure compliance with aerospace standards and safety regulations.

Responsibilities

• Assist in the design, analysis, and sustainment of fielded unmanned aircraft systems (UAS) and associated ground launch systems.
• Conduct engineering analyses using CAD, FEA, and CFD tools such as SolidWorks and ANSYS to support fielded air vehicle and launcher hardware.
• Support integration of new or replacement components into fielded aircraft and launcher hardware, including resolving obsolescence and implementing form/fit/function substitutions.
• Support structural, thermal, and mechanical testing activities for air vehicles and launch systems.
• Assist with design tasks on airframe structures and launcher components to support sustainment and integration efforts.
• Prepare clear and accurate technical documentation, engineering reports, and design presentations.
• Collaborate with cross-functional teams in systems engineering, manufacturing, testing, and other engineering disciplines.
• Help ensure compliance with aerospace standards and safety regulations, including FAA, NASA, and DoD requirements.
• Participate in prototype fabrication, integration, and validation testing for air vehicles and launch systems.
• Apply systems engineering principles and model-based design tools to support unmanned aircraft and launcher development.
• Contribute to the understanding and application of industry standards such as AS9100, FAA Part 23/25, and relevant MIL-STD specifications.
• Support efforts related to small unmanned aircraft and target drone systems, including design, analysis, and sustainment activities.
• Engage in hands-on fabrication, machining, or prototyping work as needed to support development and testing.
• Assist with data analysis and engineering calculations using tools such as Python or MATLAB to support design and test activities.
• Collaborate closely with electrical, software, and production teams to ensure successful integration of mechanical components into complete systems.
• Travel occasionally to support flight test activities and on-site integration efforts.

Essential Skills

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a closely related field.
• 0–5 years of mechanical or aerospace engineering experience, including relevant internship, co-op, or academic project experience.
• Exposure to CAD tools such as SolidWorks, CATIA, or similar platforms for mechanical design and modeling.
• Exposure to structural and finite element analysis (FEA) tools, including ANSYS or comparable analysis software.
• Basic understanding of aerodynamics, propulsion, structures, and materials relevant to aircraft and launcher design.
• Strong analytical and problem-solving skills applied to mechanical and aerospace engineering challenges.
• Ability to work hands-on in a lab or production environment as well as in an office or desk-based setting.
• Strong communication skills with the ability to collaborate effectively with electrical, software, and production teams.
• Familiarity with composite materials and fabrication methods, including wet layup and prepreg processes.
• Understanding of small unmanned aircraft or target drone systems and their mechanical and structural requirements.
• Hands-on experience with fabrication, machining, or prototyping of mechanical components.
• Internship or project experience in aircraft or unmanned system design.
• Exposure to systems engineering principles and model-based design tools.
• Knowledge of industry standards such as AS9100, FAA Part 23/25, and applicable MIL-STD specifications.

Additional Skills & Qualifications

• Experience conducting engineering analyses using CAD, FEA, or CFD tools, including SolidWorks and ANSYS.
• Familiarity with aerospace standards and safety regulations from organizations such as FAA, NASA, and DoD.
• Experience working with composite materials and advanced fabrication methods for airframe structures.
• Knowledge of target drone systems and related unmanned aircraft technologies.
• Experience with programming or data analysis using Python or MATLAB to support engineering tasks.
• Hands-on experience with composites, propulsion systems, or avionics integration is highly beneficial.
• Ability to prepare professional technical documentation, reports, and design presentations for internal and external stakeholders.
• Demonstrated ability to collaborate in cross-functional teams, including systems engineering, manufacturing, and testing groups.
• Willingness to travel occasionally to support flight test operations and field activities.

Work Environment

This position is based in Madison, Alabama, and involves a blend of office, lab, and production floor work. You will use modern engineering tools such as CAD platforms (SolidWorks, CATIA), analysis tools (ANSYS, FEA, CFD), and programming or data analysis environments (Python, MATLAB) to support design and testing. The role includes hands-on work with composite materials, fabrication methods, machining, and prototyping in a lab or production setting, as well as participation in structural, thermal, and mechanical testing of unmanned aircraft and launch systems. Occasional travel may be required to support flight tests and on-site integration activities. The work environment promotes collaboration across mechanical, electrical, software, systems engineering, manufacturing, and test teams, with a focus on safety, adherence to aerospace standards, and continuous improvement.

This is a Permanent position based out of Madison, AL.

The pay range for this position is $70000.00 - $100000.00/yr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

PERSONNEL POLICIES AND PRACTICES Work Week Monday through Friday; 8 hours per day; 40 hours per week. Different hours may be assigned to specific individuals when circumstances warrant. Holidays 10 holidays: New Year's Day, President's Day, Memorial Day, Fourth of July, Labor Day, Thanksgiving Day, Christmas Day, and 3 additional Floating Holidays (1 awarded after 3 months employment, and 2 awarded after 6 months). Personal Time Off 3 weeks per year accrued at 10 hours per month: • 1 to 5 years: 3 weeks • 5 to 10 years: 4 weeks • 10+ years: 5 weeks Paid time off (PTO) is available to use as vacation or sick leave. PTO may be accrued and carried over at the end of the year up to240 total accumulative hours after 1 year. Patriotic Service Pay The Company will compensate employees for jury duty so that there will be no loss of pay for a maximum of 40 hours. Jury duty for which compensation is provided is to be served during normal working hours. Up to 120 hours per fiscal year may be charged to administrative leave for absence due to military or National Guard obligations. The Company will pay the employee the difference between their regular base rate of pay and any pay received for military duty. Compensation Payment of wages is made by direct deposit every other Friday. Performance reviews are prepared at yearly anniversaries. Merit pay increases may be given at any time as circumstances warrant. Tuition Assistance Full-time employees may be reimbursed for expenses of pre-approved job-related coursework completed at an accredited college or university, up to a limit of $1,000 per calendar year for undergraduate studies and $2,000 per calendar year for graduate studies. A grade of A or B is required to qualify for reimbursement. An employee who voluntarily terminates employment within 1 year of undergraduate level course completion or within 2 years of graduate level course completion must refund to the Company the cost of any reimbursement received. MEDICAL CARE BENEFITS Policy The Company provides medical and dental plans through Blue Cross and Blue Shield of Alabama. The Company pays 100% of the premium for employees and 90% of the premium for family coverage. Coverage begins on date of hire. Premiums per pay period for medical and dental coverage are: Blue Access Gold Plan: Employee Only: $0 Employee + Child Dependent: $25.64 Employee + Adult Dependent: $29.24 Family: $55.13 Blue Choice 100 (Merit): Employee Only: $46.01 Employee + Child Dependent: $110.75 Employee + Adult Dependent: $121.26 Family: $186.26 Hospitalization Coverage - Blue Access Gold Plan 100% after $250 per day hospital co-pay for days 1–5 for each admission. Outpatient 100% after $250 co-pay. Calendar Year Deductible: $600 Individual; $1,200 Family Office Visits: $30 Primary Care; $50 Specialist See Plan description booklet for more information. Hospitalization Coverage - Blue Choice 100 (Merit) 100% after $150 per day hospital co-pay for days 1–5 for each admission. Outpatient 100% after $150 co-pay. Calendar Year Deductible: $100 Individual; $200 Family Office Visits: $20 Primary Care & Specialist See Plan description booklet for more information. VISION CARE BENEFITS The Company voluntarily provides a Vision Plan through VSP. Premiums per month are: Vision Care Premium: Employee Only: $4.00 Employee + One: $5.80 Employee + Family: $10.39 Plan Frequencies Exam every 12 months Lenses every 12 months Frames every 24 months Co-payment If using a network provider, each member's co- payment at the time of service are: Exam: $10; Lenses and/or frames: $20 DEATH BENEFITS PLAN Basic Life Insurance Mutual of Omaha. The Company pays 100% of premium. Coverage amount is $200,000. Effective date is first of the month following date of hire. Supplemental Life Insurance Mutual of Omaha. Supplemental life insurance is available to employee, spouse, and children. Effective date is first of the month following date of hire. Premium is calculated based on schedule on file in Human Resource Department. Accidental Death & Dismemberment Policy Mutual of Omaha. The Company pays 100% of premium. Coverage amount is $200,000. Effective date is first of the month following date of hire. INCOME PROTECTION PLANS Short Term Disability Mutual of Omaha. The Company Pays 100% of premium. Coverage amount is 60% of tax-free weekly salary. There is a 15-day waiting period. Effective date is first of the month following completion of introductory period. Long Term Disability Mutual of Omaha. The Company pays 100% of premium. Coverage amount is 60% of tax-free monthly salary. There is a 90-day waiting period. Effective date is first of the month following completion of introductory period. SAVINGS PLAN 401(K) Plan is available to all eligible employees. Contributions can be made by the employee beginning with the first payroll check. The Company will match the employee percentage contributed up to 5% starting in the first payroll check.

This is a fully onsite position in Madison,AL.

This position is anticipated to close on Aug 31, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.