Master thesis; f​/m​/x - Design Smart Roller

Master thesis (f/m/x) - Design of a Smart Roller

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The Institute of Structures and Design works on the development and optimization of materials and their processing and joining technologies, from fundamentals up to the construction of full-scale demonstrators. Part testing and validation in state-of-the-art test facilities, both ground-based and in-flight, are also part of daily work at the Institute. Work is focused on aerospace-grade polymer composites, fibre-ceramics, and other hybrid materials, with researchers employing new multidisciplinary design tools and digital models to support hardware development.

The Department of Component Design and Manufacturing Technologies at the Institute in Stuttgart primarily deals with the development, manufacturing, and testing of novel high-performance structures for aircraft engines, aircraft, and land-based vehicles. The focus is on innovative lightweight construction methods for reduced weight, improved performance, increased reliability, and long-term economical manufacturing.

Thermoplastic Automated Fibre Placement (AFP) is seen as a key technology for the realisation of components in the next generation of lightweight passenger aircraft. Recent investigations at DLR have shown that smart roller technology, originally developed for thermoset materials and used to monitor composite compaction in real-time, can be adapted to the high processing temperatures of thermoplastics; >400°C.

This thesis "Design of a Smart Roller for High-temperature Thermoplastic AFP" work is a cooperation between DLR and UBC and includes a temporary stay in Vancouver, Canada.

• familiarisation with the AFP process and manufacturing equipment at DLR Stuttgart
• selection and testing of material alternatives for the electrically conductive layer at UBC in Vancouver, Canada
• optimization of the current smart roller manufacturing concept at UBC in Vancouver, Canada
• test and validation in a real use scenario at the DLR AFP facility in Stuttgart

• student (f/m/x) in the field of materials science, aerospace engineering, mechanical engineering or a comparable engineering degree program
• fluent English

We look forward to getting to know you!

If you have any questions about this position (Vacancy-) please contact:
Sebastian Nowotny
Tel.:

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