3D Printing Intern

Summary

The 3D Printing Intern position at Jaycon Systems LLC supports the engineering team in producing high-quality prototypes and functional parts using FDM 3D printers. This role involves hands-on work preparing, printing, and post-processing thermoplastic components, as well as assisting in design and testing activities for product development. The intern will contribute to mechanical design projects, help maintain FDM 3D printing equipment, and gain experience in the full cycle of rapid prototyping and additive manufacturing within a product design and manufacturing environment.

Duties & Responsibilities

1. Operate, maintain, and troubleshoot FDM 3D printers (e.g., nozzle cleaning, bed leveling, extruder calibration) to ensure optimal performance.
2. Prepare and slice 3D models using slicing software (e.g., PrusaSlicer, Cura, Bambu Studio), optimizing layer heights, infill density, wall thickness, and support structures.
3. Post-process printed parts, including support removal, sanding, heat-set insert installation, and surface finishing.
4. Collaborate with engineers on designing and prototyping enclosures, fixtures, and other mechanical components for FDM manufacturability (DFAM).
5. Review CAD models for printability, overhang constraints, and recommend design improvements.
6. Keep detailed logs of print jobs, manage filament inventory, and maintain filament storage/drying units.
7. Inspect printed parts for dimensional accuracy, bed adhesion issues, layer bonding, and overall quality.
8. Assist in research and testing of materials (e.g., PLA, ABS, PETG, TPU, Nylon) and printing techniques to improve print quality and strength.

Necessary Skills & Knowledge

1. Understanding of FDM 3D printing processes, thermoplastic materials, and thermal behavior (warping, bed adhesion, cooling).
2. Experience operating FDM printers and using slicing software (Cura, PrusaSlicer, Bambu Studio, or similar).
3. Proficiency in CAD modeling (SolidWorks, Fusion 360, or similar).
4. Knowledge of mechanical design principles, tolerances, and design for additive manufacturing (DFAM).
5. Strong attention to detail and quality control.
6. Analytical and problem-solving abilities (e.g., diagnosing print failures, stringing, or clogging).
7. Effective teamwork and communication skills.

Requirements

1. Currently pursuing or recently completed a Bachelor’s degree in Mechanical Engineering or a related field.
2. Hands-on experience with FDM 3D printers and slicing software (required).
3. Experience designing complex mechanical parts or assemblies (preferred).
4. Familiarity with thermoplastic post-processing techniques and hardware integration (e.g., heat-set inserts).
5. Availability to work on-site in Palm Bay, FL.

Working Environment

1. Work in a hands-on prototyping lab with mechanical and electrical engineers.
2. Exposure to additive manufacturing processes and materials testing.
3. Fast-paced, project-oriented environment with opportunities to apply engineering and design skills.
4. Collaboration across design, prototyping, and manufacturing teams.

Job Relationships

Reports to: Solutions Architect and Test Lab Generalist

Works closely with: Design & Development Department

Performance Metrics

1. Print Accuracy & Dimensional Quality
2. Project Timeliness & Lab Throughput
3. Design & Print Optimization Effectiveness