ESAero Internship

Empirical Systems Aerospace (ESAero) is an industry leader in advanced aerospace solutions, specializing in the design, manufacturing, and integration of unmanned aerial systems (UAS) and other cutting-edge aircraft technologies. Located in San Luis Obispo, CA, ESAero partners with a variety of companies to develop next-generation aviation technologies, with a strong focus on efficiency, scalability, and high-performance engineering.

As an engineering intern, I focus on increasing production throughput and optimizing manufacturing processes. My role is highly adaptable, meaning I contribute wherever I am most needed—whether that’s designing parts or fixtures to assist production, building and setting up workbenches for technicians, or improving workflows to make manufacturing smoother and more efficient. My work is centered around manufacturing and production support, ensuring that engineers and technicians have the tools and resources they need to keep operations running efficiently.

When production or engineering needs custom fixtures, tooling, or specialized components, I use SolidWorks to create 3D models, technical drawings, and prototypes. These designs help with everything from assembly and fabrication to testing equipment setup. Whether it’s 3D printing custom tools, designing fixtures for streamlined production, or creating structural assemblies, I focus on making practical, manufacturable solutions that directly support production needs.

My contributions go beyond CAD work—whenever needed, I jump in to help with hands-on tasks that improve production efficiency. This has included building and setting up dozens of workbenches for technicians, organizing tools and equipment, and physically assembling components to ensure production runs smoothly. I take on a wide range of projects based on what will have the biggest impact on manufacturing efficiency, ensuring that both engineers and technicians have the resources they need to keep things moving.

A large part of my role involves creating and maintaining structured systems in Excel to improve work instruction clarity, equipment standardization, and vendor tracking. While I don’t write work instructions myself, I ensure that terminology, part numbers, and vendor selections remain consistent across all documentation. I also work in BOM validation to verify is helps streamline communication between engineers, technicians, and purchasing teams, reducing confusion and improving efficiency.

Part of my role has been getting various CNC equipment ready for use in production. This includes setting up and calibrating new machines, ensuring proper tooling is in place, and validating machine readiness for efficient operation. By working alongside technicians and engineers, I help integrate CNC systems smoothly into the manufacturing workflow, reducing downtime and ensuring repeatable, high-quality production.

Another part of my role is sourcing and providing technicians with the right tools for the job. If a technician needs a specialized tool for a task, I research vendors, find the best options, and ensure compatibility with existing processes. By providing the right tools and equipment, I help eliminate bottlenecks and improve efficiency across the production floor.