Intern – Vehicle Integration

System Assembly & Integration
• Assist in mechanical integration of vehicle components such as gondolas, envelope structures, payload modules, and tether assemblies.
• Support electrical wiring, harness routing, and connector interface between avionics, power, and communication subsystems.
• Participate in integration of radar, communication, power, and control systems within the vehicle architecture.
• Ensure proper mounting, vibration isolation, and structural balance of all subsystems.
Subsystem Interface Management
• Work with design teams to ensure compatibility and alignment between structural, mechanical, electrical, and software subsystems.
• Support Interface Control Document (ICD) preparation and maintenance for each system.
• Identify and resolve integration bottlenecks during prototype assembly or test campaigns.
Testing & Validation
• Participate in ground validation and pre-flight system checks, including continuity, telemetry, and power distribution tests.
• Assist in environmental and functional testing vibration, thermal, EMI/EMC, and tether load evaluations.
• Support end-to-end integration testing before flight, ensuring communication links, sensors, and actuators perform as expected.
• Help in developing test logs, checklists, and integration reports for documentation and traceability.
Vehicle Instrumentation
• Assist in installation and calibration of sensors, flight controllers, and telemetry modules.
• Support data acquisition setup for pressure, altitude, IMU, and GPS sensors.
• Ensure proper grounding, shielding, and signal integrity for all flight electronics.
Software & Communication Integration
• Support configuration of onboard computers, embedded software, and data buses (UART, CAN, SPI, I2C).
• Validate telemetry and command links between vehicle systems and the ground control station.
• Participate in debugging communication or data relay issues during test campaigns.
Safety, Quality & Compliance
• Follow integration and handling safety procedures for high-pressure systems, hydrogen/helium operations, and electrical subsystems.
• Ensure all integration activities comply with Red Balloon’s quality assurance and testing protocols.
• Participate in pre-launch safety reviews and post-flight recovery assessments.
Documentation & Reporting
• Maintain integration logs, configuration sheets, and wiring schematics for each vehicle.
• Support preparation of system integration manuals, bill of materials (BOMs), and update drawings as per design changes.
• Assist in documenting lessons learned from integration campaigns for future builds.
Cross-Functional Collaboration
• Coordinate closely with mechanical, avionics, power, payload, and control system teams.
• Participate in integration reviews and contribute suggestions for improving modularity and assembly efficiency.
• Support launch and recovery operations under supervision of vehicle engineers.