Master Thesis (d/m/w) im Bereich Fertigungsprozesssimulation
// Role Summary
Airbus Helicopters is seeking a Master's student to join their aircraft door department in Donauwörth, Germany, focusing on the simulation of manufacturing processes for thermoplastic composites.
// Key Responsibilities
- Develop and validate a simulation strategy for predicting interface bonding behavior in hybrid components.
- Conduct literature reviews, implement modeling approaches, and calibrate numerical models using experimental data.
- Validate models with mechanical data to assess predicted interface quality and prediction accuracy.
- This is a 6-month thesis position starting October 2026, with a 35-hour work week and flexible working hours.
- Requires a strong academic background in aerospace, lightweight construction, mechanical engineering, or a related field, with knowledge in composite mechanics and FEA.
// Role Specification
Master Thesis: Manufacturing Process Simulation (m/f/d)
Airbus Helicopters is looking for a Master's student to support the Aircraft Doors department in Donauwörth, Germany. This is an excellent opportunity to gain practical engineering experience through a Master's thesis.
Role and Responsibilities:
The use of thermoplastic fiber composites, such as C/PAEK, offers significant lightweight potential in aircraft construction. However, for hybrid components manufactured using injection overmolding, the interface strength between the organosheet and the injection-molded part is a critical, process-dependent factor. The objective of this Master's thesis is to develop and validate a simulation strategy for predicting this interface bonding behavior.
- Conduct a comprehensive literature review on interface healing models, bonding mechanisms of thermoplastic composites, and macro/meso simulation approaches.
- Implement and evaluate various modeling approaches to accurately capture the bonding zone.
- Utilize existing experimental data for calibration and assessment of numerical model parameters.
- Validate the numerical models against experimental mechanical data to evaluate the predicted interface quality.
- Discuss validation results in detail, including a critical assessment of prediction accuracy, sensitivities, and simulation limitations.
- Document and present the developed simulation methodology and research findings.
Your Location:
Based in Donauwörth, on the banks of the Danube near Augsburg, we develop helicopters from the initial concept to the flight-ready product. Experience their take-off and landing on our own test flight field.
What We Offer:
- Attractive compensation and a balanced work-life schedule with a 35-hour work week (flexible hours).
- An international environment with opportunities to build global contacts.
- Work with modern and diverse technologies.
- You will be treated as a full team member, closely collaborating with interfaces and participating in weekly team meetings.
- Access to the Generation Airbus Community for networking.
Required Skills and Qualifications:
- Currently enrolled as a full-time student in Aerospace Engineering, Lightweight Construction, Mechanical Engineering, Computational Engineering, or a comparable field.
- Sound knowledge in the mechanics of fiber-reinforced composites and nonlinear Finite Element Analysis (FEA).
- Experience with CAE software (e.g., Moldflow, Moldex3D, Inspire).
- Initial experience in 3D modeling with CATIA is desirable.
- Basic programming skills (e.g., Python) are advantageous.
- Fluent German and English language skills.
Please upload the following documents: Cover letter, CV, relevant certificates, and proof of enrollment.
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