Intern, Mechanical Engineer (Spring/Summer 2027)

Heron Power is a startup company building cutting-edge power electronics for the 21st-century grid. We aim to debottleneck the growth of electricity generation and consumption with scalable, innovative, and less costly hardware solutions, accelerating the electrification of everything.

Our first goal is to build better converters (inverters & rectifiers) to connect large-scale renewables, storage, and loads to the grid. Heron Power’s leadership team is made up of seasoned veterans who have designed and shipped gigawatts of power conversion products over the past decade.

We understand that no one individual knows everything.  We will all learn a lot together and from each other.  We strive to build a collaborative, enriching environment conducive to personal, technical, and career growth.  You can expect to work in a dynamic and collaborative environment, driven by first principles engineering, solving difficult problems.

As a Mechanical Engineer Intern, you will work alongside a team of experienced engineers to design, develop, and validate cutting-edge medium-voltage power electronics systems. You will design a wide range of associated parts and assemblies using a first principles design approach. Your role will involve performing a variety of tasks, including CAD, analysis, prototyping, testing, and hands-on work. You will collaborate closely with electrical, test, and manufacturing engineering teams, as well as external suppliers.

This internship is ideal for students passionate about mechanical design and electronics who are excited to build scalable, efficient, and reliable energy systems that will shape the future of the grid.

• Design parts and assemblies for power converters, such as enclosures, plastics, heatsinks, insulators, transformers, connectors, PCBAs, bolted joints, and adhesive joints

• Employ manufacturing processes such as fastening, sheet metal bending, stamping, injection molding, diecasting, extruding, and dispensing

• Design with a first principles approach, optimizing parts through analysis (e.g. structural, thermal, tolerance)

• Create 3D designs and 2D drawings using CATIA V6/3DX

• Perform hands-on work such as prototyping and testing

• Collaborate with different engineering disciplines, including mechanical, electrical, manufacturing, and reliability teams, as well as external partners and suppliers

• Own parts and assemblies from initial concept to high volume production

We have a short list of must-have requirements. We prioritize a strong grip on first principles, hands-on skills, and a sense of initiative. Domain-specific knowledge and experience will help determine the career level for each hire.

Must-Have Requirements 

• Currently pursuing a Bachelor's, Master's, or PhD in Mechanical Engineering, Mechatronics, or a related field (and will maintain student status throughout the duration of the internship)

• Strong history of designing mechanical parts or assemblies through individual or group projects (recommend showcasing examples of past work with a website or PDF portfolio)

• Proficiency with at least one 3D CAD program (bonus if there is experience with CATIA V6/3DX)

• Strong engineering fundamentals including a basic understanding of electronics

• Familiarity with a first principles design approach

• Excellent communication and interpersonal skills

• Ability to work independently and as part of a team

• Strong problem-solving skills and attention to detail

Nice-to-Haves

• Prior internship, co-op, or research experience in mechanical design or validation.

• Experience with high volume manufacturing and processes such as fastening, sheet metal bending, stamping, injection molding, diecasting, extruding, and dispensing

• Experience with PCBAs, connectors, fuses, and other electronic components

• Experience designing outdoor-rated industrial enclosures

• Experience with FEA, CFD, multi-physics modeling, or associated software (Ansys, MATLAB, Python, Simulink, StarCCM, etc.)

• Experience with GD&T and tolerance analysis

• Experience with reliability and validation testing, as well as DFMEAs

• Experience with product lifecycle management (PLM) and controlled release processes

• Experience with medium voltage (34.5kV) or grid-related products, such as converters, switchgear, circuit breakers, insulation, and shielding

If you are passionate about technology and enjoy working in a fast-paced environment, we would love to hear from you. Join us in accelerating the electrification of everything at Heron Power.