Job Description:

This internship requires process development and testing of bolted connections for satellite hardware. The SPINtern will evaluate, improve and expand upon internal processes, defining selection of fasteners, torques and secondary retention methods, based on industry standards.

The desired outputs of the project are:

1. Creation of a database and/or calculation tool of torques for various bolt materials, thread engagements, and joint parameters that can be used by the engineering team

2. Experimental verification of calculation tool

3. Identification of secondary retention method options for these fasteners such as adhesives, heli-coils and thread lock, and their efficacy.

Standardised design, calculation methods, and assembly processes are key to quality and consistency in any engineering project. This internship offers hands-on R&D and testing of bolted connections for satellite hardware which can be critical to the survival of Space missions. The Spintern will evaluate current standards and improve and expand upon Space Forge processes, defining selection of fasteners, torques and secondary retention methods.

The project is to standardise applied torques based on joint and fastener parameters. The desired deliverables that the intern shall work towards are:

1. Creation of a calculation tool that can be used by the engineering team that can provide torques for various bolt and joint parameters

2. Verification of this calculation tool using experimental methods on hardware defined by the intern

3. Investigate and evaluate options for anti-vibration secondary retention for fasteners such as adhesives, lock washers and thread lock

The project will involve researching best practices in line with industry standards, followed by verifying and testing results experimentally. The SPINTern will design the experiments, carry out risk assessment & test planning, create test coupons on CAD and CNC machines, conduct the tests, and record and document the results that will inform standardisation.

The successful applicant should have the following qualities and abilities:

• The intern shall be partway through a Bachelor’s or combined Master’s degree in an engineering field.

• Knowledge of A-level or early undergraduate level calculations related to stress and friction is required.

• A mechanical, manufacturing, or aerospace focus is a natural fit for this internship, but is not a minimum requirement.

• An interest in the practical side of engineering would be beneficial, as it is expected the applicant shall be exposed to significant hands-on activities.

Process details:

• 8 weeks minimum fixed term contract to be agreed with successful candidate

• 5 days holiday to be taken during the placement

Working at Space Forge:

Space Forge is an advanced materials company based in Cardiff. We were established in 2018 by two co-founders and are a VC-funded start-up-of-scale established in both the UK and the US. We are currently 72 people with both Semiconductor sector (five PhDs) and Space sector (40 missions) experience, and have already built two satellitesWe are one of the world's first In-Space Manufacturing companies. Our goal is to exploit the extreme temperature, microgravity and ultra-high vacuum conditions available in low earth orbit to manufacture materials that cannot readily be grown terrestrially.