Manufacturing Engineering Intern Summer 2025

Thea Energy is building an economical and scalable fusion energy system utilizing arrays of mass manufacturable magnets and dynamic software controls. Commercial fusion energy can uniquely provide a abundant source of zero-emission power for a sustainable future. Thea Energy is leveraging recent breakthroughs in computation and controls to reinvent the stellarator, a scientifically mature form of magnetic fusion technology. Thea Energy was founded in 2022 as a spin-out of the Princeton Plasma Physics Laboratory and Princeton University, where the stellarator was originally invented. Thea Energy is currently designing its first integrated fusion system, Eos, based on its planar coil stellarator architecture which will produce fusion neutrons at scale and in steady-state.

Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.

Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. By creating a diverse environment, we will bring new ideas and approaches to solving some of the world’s hardest (and most important) problems. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran’s status, or other characteristic protected by applicable laws and regulations.

Mechanical Engineering Interns will develop and exercise their design, analysis, and hands-on skills to support prototyping and stellarator design activities. Activities may include CAD and/or FEA model development, and will culminate in the delivery of functional custom components, tooling, fluid systems, and test equipment. (This role will require at least 3 days onsite per week.)

Manufacturing Engineering Interns will support process development, fabrication and assembly, equipment design, and testing for Thea Energy’s HTS magnet prototyping programs. A Manufacturing Engineering intern will be exposed to the physical and strategic aspects of the manufacture of HTS magnets, and will get hands-on experience operating equipment. 

Magnet Engineering Interns will support the design, build, testing, and performance analysis of Thea Energy’s custom HTS magnets. Activities may include: design of magnet components and tooling, development of FEA simulations (electromagnetic, mechanical, or thermal), operation of cryogenic tests and test equipment, and development of custom analytical tools to assess magnet performance. 

Test Engineering Interns will support the development and execution of test equipment, facilities, and operations associated with Thea Energy's custom HTS magnets and magnet-related hardware. To enable test execution and analysis of performance data, this role may include aspects of mechanical, electrical, instrumentation, and software engineering.

Fusion Technology interns will assist scientists and engineers in designing and developing various subsystems for Thea Energy’s stellarator fusion devices. 

Plasma Physics interns will work with scientists to model magnetically confined high temperature fusion plasmas using sophisticated computational tools. 

Stellarator Optimization Interns will support computational physicists and plasma physicists in optimizing stellarator magnetic geometry for Thea Energy’s next-generation fusion devices.