General Dynamics

Mechanical Engineering Intern - General Dynamics Applied Physical Sciences- Summer 2025  [Classified]

My internship at General Dynamics Applied Physical Sciences introduced me to the complex engineering behind the sonar systems used by the U.S. Navy. Although the broader program and many technical details remain classified, my work focused on developing the specialized tools and components required to manufacture and test large acoustic arrays.

One of my primary projects was designing a hydrophone tray used during the production of acoustic sensors. The tray needed to securely position sensitive components while withstanding a manufacturing process that exposed it to temperatures of approximately 180°F. I developed the design in SolidWorks, compared potential materials and manufacturing methods, performed cost analyses, and used finite element analysis to evaluate whether the tray could withstand the expected structural and thermal conditions. I then produced engineering drawings using GD&T and ASME standards and helped fabricate the final component.

I also helped improve a long drill-extension system used during assembly. The original tool deflected by nearly four inches under its own weight, making it difficult to maintain accuracy. I designed and fabricated a stabilizing solution that reduced the deflection to approximately half an inch, transforming an unwieldy tool into one that technicians could use more precisely and reliably.

These projects allowed me to experience the complete engineering process—from identifying an operational problem and developing a CAD model to analyzing, machining, testing, and refining a physical solution. More importantly, they taught me that even the most advanced defense systems depend on thoughtfully designed tools and manufacturing processes. The experience strengthened my interest in underwater sensing and showed me how careful mechanical engineering can contribute to technologies that protect naval personnel and support national security.