Relativity Space Internship
Additive Manufacturing Engineering Intern |
Relativity Space Internship
Additive Manufacturing Engineering Intern
Summer 2026 | Long Beach, CA
Skills: Laser Powder Bed Fusion, Design of Experiments, Metallography
Core Values: Wonder, Audacity, Relentlessness, and Humanity
Preventative Maintenance Process Development
Increase Production Reliability
I was set out to develop a metal PBF build as a practical test to verify if a machine is properly calibrated and printing to spec. The image to the left is a model which accomplishes a similar objective for FDM (extruded plastic) 3D printers.
Background Research & Experimentation
After two months of experiments, research into various industry-standard practices for PBF, and learning about company history with similar maintenance builds I investigated whether this kind of test is capable of providing the value the team initially expected. After analyzing my own parts using methods such as metallography, caliper measurements, and visual inspection, I ultimately determined that such a build would not reliably indicate drift in machine calibrations.
Scope Shift
With the same direction in mind, I focused my learnings onto a specific piece of engine hardware with tight tolerances and known points of failure. I developed new coupons specialized for the specific part which could indicate if a machine needed recalibration before building an entire piece of flight hardware. This specialized build has the potential to save $100,000’s if it can prevent even a few failed prints.
Note: The images are merely visual aids to describe my work, and are not directly representative of the work I completed
Printed Threads
Minutes Printing / Hours of Machining
The production floor needed a small computer to test each unit after assembly, and I was tasked with souring an enclosure for this device.
Robust DOE and Analysis
This encompassed everything from exploring preexisting solutions, to quoting custom designs, and eventually creating a custom enclosure using the SOLIDWORKS sheet metal design suite.
Hardware Integration
I began prototyping first using foam-core to validate measurements, before then creating a functional 3D printed proof of concept.
The final step was, again, preparing quotes and ensuring all DFM constraints were satisfied, and then the project was handed off to purchasing for final release of the order.
Note: The images are merely visual aids to describe my work, and are not directly representative of the work I completed
Printer Alarm System
Reduce Failed Prints
I was set out to develop a metal PBF build as a practical test to verify if a machine is properly calibrated and printing to spec. The image to the left is a model which accomplishes a similar objective for FDM (extruded plastic) 3D printers.
Machine Integration
After two months of experiments, research into various industry-standard practices for PBF, and learning about company history with similar maintenance builds I investigated whether this kind of test is capable of providing the value the team initially expected. After analyzing my own parts using methods such as metallography, caliper measurements, and visual inspection, I ultimately determined that such a build would not reliably indicate drift in machine calibrations.
Sustainable Sendoff
With the same direction in mind, I focused my learnings onto a specific piece of engine hardware with tight tolerances and known points of failure. I developed new coupons specialized for the specific part which could indicate if a machine needed recalibration before building an entire piece of flight hardware. This specialized build has the potential to save $100,000’s if it can prevent even a few failed prints.
Note: The images are merely visual aids to describe my work, and are not directly representative of the work I completed