Bettis Atomic Laboratory Internship

*Work done under DOE L Clearance

• Relevant Skills: Creo, GD&T & ASME B/Y14.5 Standards, Structural Analysis (MathCAD), Product Development, DFMA, Rapid Prototyping/3D Printing, COTS Component Integration, Mechanical Testing and Analysis, Technical Documentation, Procurement

Background

During Summer 2025, I interned at the Bettis Atomic Laboratory, where I supported the development of specialized systems for spent-fuel examination equipment. Due to national security considerations, only high-level details of this work can be shared.

Goals

I was responsible for leading the end-to-end design and prototyping of a high-value payload leveling mechanism that required stringent accuracy and reliability. The project demanded close adherence to ASME standards, integration of COTS components, and collaboration across multiple engineering disciplines.

Design and Execution

• Developed multiple functional concepts in Creo, applying ASME design standards.
• Conducted structural analyses in MathCAD across varied load cases to validate safety factors
• Procured specialty alloys and high-tolerance parts from multiple vendors, reducing prototype lead time by several weeks
• Applied rapid iteration through additive manufacturing and commercial off-the-shelf (COTS) components
• Collaborated with cross-functional engineering teams to resolve integration challenges and ensure proper fit with larger assemblies

Outcome

The resulting prototype achieved ±0.1° leveling accuracy, improving reliability and safety of spent-fuel examination systems. Beyond development of technical skills, this experience provided me with hands-on exposure to the intersection of mechanical design, procurement, and nuclear security.