Material & Processes Engineering Intern

About the role

As a Materials & Processes Engineering Intern at Canopy Aerospace & Defense, you will own the execution of formulation trials for thermal barrier materials, guiding polymer experiments from initial benchwork through thoroughly documented routines. You will hands-on mix and fabricate samples, directly revealing how composites respond to plasma exposure and demanding load conditions in extreme environments. Your role involves documenting every test result with precision so that future teams can understand material behavior during reentry stresses and other critical scenarios. You will design and develop resin systems that meet strict thermal protection targets for spacecraft and hypersonic vehicle applications. Preparing batches of ceramic precursors and carefully monitoring their curing behavior under controlled conditions will become a core part of your responsibilities. You will fabricate tile and panel prototypes that mimic actual vehicle geometries, following established procedures to ensure consistency and repeatability. Running furnace sequences to observe material transformations as heat levels rise will require strict adherence to safety protocols and test schedules. You will measure char depth and dimensional strain to evaluate how samples endure intense thermal exposure, translating observations into actionable data. Assisting with meticulous data capture will ensure engineers can compare performance across multiple formulations and iterate effectively. Coordinating with test chambers and internal teams is necessary to schedule runs efficiently and keep experiment timelines on track.

Key facts

What you'll do

• Drive formulation trials for thermal barriers, guiding polymer experiments from bench concept to documented standard routines.
• Perform hands-on mixing and sample fabrication to reveal how composites handle plasma exposure and mechanical loads in harsh testing conditions.
• Document each test result in detail so that future engineering teams understand material behavior under reentry stresses and thermal cycling.
• Design resin systems that meet specific thermal targets for spacecraft protection and structural integrity in high-heat scenarios.
• Prepare batches of ceramic precursors and monitor how they cure under set conditions to ensure consistency and repeatability.
• Fabricate tile and panel prototypes that mimic vehicle shapes for testing, following established procedures to maintain fidelity to design intent.
• Run furnace sequences to observe how materials change when heat levels rise, requiring strict adherence to protocols and safety requirements.
• Measure char depth and strain to judge how samples endure intense thermal exposure and mechanical deformation.
• Assist with data capture and organization to ensure engineers can compare performance across multiple formulations and test conditions.
• Coordinate with test chambers and internal teams to schedule runs and keep experiment timelines on track and resource-efficient.
• Update detailed records that trace each sample from raw ingredients through processing to evaluated results, maintaining full traceability.
• Support the development of next-generation thermal protection materials for spacecraft and hypersonic vehicles operating in extreme environments.
• Contribute to the evaluation of advanced composite substrates and high-temperature resin systems through systematic testing and analysis.
• Translate laboratory observations into clear documentation that guides the evolution of material formulations and manufacturing approaches.
• Collaborate with engineers and scientists to prototype new TPS materials from first principles in a structured experimental framework.

Requirements

• Study materials science or a related engineering field at an accredited institute to build a foundational understanding of material behavior.
• Complete at least two terms focused on chemistry or similar subjects to ensure familiarity with chemical reactions and material interactions.
• Understand how to read safety data sheets and follow handling protocols to maintain a safe and compliant work environment.
• Commit to a full academic year starting in August 2026 to provide continuity and depth to project contributions.
• Work in the United States without sponsorship for this role, as specified in the engagement terms and legal requirements.
• Hold a current driver license and arrange your own transport to the job site, given the location and operational needs.
• Be physically present and work on-site in Littleton, Colorado, without remote options to ensure seamless integration with the team.
• Responsible for providing your own transportation to the job site and managing logistics related to commuting.

Nice to have

• Experience mixing chemicals or working in lab environments is preferred to accelerate onboarding and contribution.

Practical notes

• Interns are expected to commit to a full academic year beginning in August 2026 to ensure alignment with project timelines and learning objectives.
• You must be physically present and work on-site in Littleton, Colorado, as this role does not offer remote or hybrid arrangements.
• You are responsible for providing your own transportation to the job site and managing all related travel arrangements independently.
• This internship is paid at $26.25 per hour, reflecting the technical nature of the work and the level of responsibility involved.
• You must have the legal right to work in the United States without company sponsorship to comply with hiring and documentation requirements.