Raphael Kalatzis, SEAS ’26, Houston, TX
This summer, I was blessed with the opportunity to intern at a sizable engineering firm in the defense sector. As a mechanical design intern, much of my experience revolved around the use of 3D modeling and simulation software. Throughout the summer, I spent much time working with staff from the company’s manufacturing factory. Most of my projects served to address inefficiencies or difficulties presented in the manufacturing process.
My workflow typically began by gathering as much information as possible about the problem that I was tasked with solving. Specifically, I would observe the relevant steps as manufacturing took place in front of me, speak with the workers performing those steps, as well as gather context from manufacturing supervisors. After understanding the problem, I learned that the first step to creating a solution is to identify and establish constraints. Constraints, or characteristics of the problem that rule out certain solutions, often came in the form of dimensions, unusual geometries, material types, accessibility, and fragility of the product. After defining my constraints, I would begin to design the solution using the 3D modeling software Creo Parametric. Throughout the design process, I learned the value of consulting fellow engineers on my team and drawing on their experience to deliver the best solution possible. Once satisfied with the design, I would begin the process of implementing it (which often meant the use of 3D printers). Following implementation, it was also my responsibility to ensure that the solution integrated smoothly and really did solve the problem.
In repeating this workflow for various projects assigned to me over the summer, I learned the importance of collaboration – especially between departments – in the context of design engineering. By establishing an open line of communication between my own mechanical design department and the manufacturing facility, my fellow coworkers and I were able to find patterns in any manufacturing inefficiencies that occurred due to the nature of the design process. By finding these patterns, our department was able to propose changes in product design that would boost manufacturing efficiency whilst maintaining the same standard of functionality.
On the whole, this internship enabled me to advance my skills as an aspiring mechanical engineer. I am grateful to Penn Career Services for the help they have provided along the way!
This is part of a series of posts by recipients of the 2024 Career Services Summer Funding Grant. We’ve asked funding recipients to reflect on their summer experiences and talk about the industries in which they spent their summer. You can read the entire series here
