Intern - Mechanical Engineer (Spring 2027)
Posted Sep 1, 2026 · We last checked this listing on Oct 6, 2026
Likely interview questions for this role
Written from this job description, not a generic list. Each one notes what the interviewer is really checking.
About your past
Tell me about a mechanical design project you worked on in school or on a team. What was your part?
What they are checking: Whether they have done hands-on design work and can explain their own contribution.
Tell me about a design that did not work the first time. What did you change?
What they are checking: Whether they learn from testing and iterate rather than defending a first idea.
How have you worked with electrical or software teammates on a shared project?
What they are checking: Whether they can collaborate across disciplines, which product design at Plexus requires.
What do you hope to learn during a fall co-op term, and how will you measure that you got it?
What they are checking: Whether they have clear goals and will own their own learning.
What would you do
Plexus builds things like surgical systems and aerospace hardware. How would designing for those differ from a consumer product?
What they are checking: Whether they appreciate the higher stakes and documentation needed in regulated industries.
You are given a task and you are not sure where to start. What do you do?
What they are checking: Whether they ask good questions and take initiative instead of waiting quietly.
About the work
What CAD software have you used, and how did you use it on a real project?
What they are checking: Whether they can model parts and assemblies well enough to contribute early.
How do tolerances on a drawing affect whether a part can actually be manufactured?
What they are checking: Whether they understand that design choices drive cost and difficulty on the shop floor.
Walk me through how you would design an enclosure that keeps electronics cool.
What they are checking: Whether they can reason about heat transfer and airflow from basic engineering principles.
How would you choose between machining, sheet metal or injection molding for a part?
What they are checking: Whether they understand basic manufacturing processes and how volume and cost drive the choice.
Practice this interview out loud.
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Practice this out loudThe full job description
As published by Plexus.