Vitrified-bond diamond grinding tools enable the ultra-precise machining of cemented carbide as well as silicon and sapphire wafers. In this project, you will lay the foundation for their further development by investigating the influence of mixing parameters and raw material properties on ceramic sinter mixtures, thereby contributing to the development of next-generation vitrified bonds.

You will support us with:

• Conducting mixing experiments and raw material characterizations
• Analysis of particle size and distribution within the mixture
• Model development for predicting mixing quality

Ideally you have:

• Interest in laboratory work
• Experience using microscopy equipment
• Calm and tidy approach to work

Within the Collaborative Research Center SFB 1368 (TPC04), we investigate the influence of oxygen-free atmospheres on the grinding process. In this student thesis, you will develop and validate simulation models to capture tribomechanical loads and the effect of oxygen on grinding. Your work will contribute to a deeper understanding of the underlying process mechanisms under oxygen-free conditions.

You will support us with:

• Developing and validating simulation models in Ansys Mechanical
• Deriving simulation input parameters from existing experimental data
• Evaluating and interpreting simulation results
• Documenting the simulation models and findings

Ideally you have:

• Basic knowledge of the finite element method (FEM)
• Interest in simulation and manufacturing technology
• An independent and structured way of working

The implantation of hip prostheses can improve patients’ quality of life. Bimodular implants allow for better adaptation to patient-specific biomechanics but may exhibit damage at the modular interface. To further optimize these implants, factors influencing such damage are investigated. In this project, you will contribute to the advancement of hip implant design.

You will support us with:

• Conducting experiments
• Determination and use of adhesion coefficients
• Performing and evaluating FEM simulations (ANSYS) to analyze loads and contact pressures
• Analysis of damage in hip implants

Ideally, you will have:

• Affinity for manufacturing engineering
• Interest in experimental work
• Independent and structured way of working

In this project, you will develop a method for the automated detection of geometric features (e.g. pockets, bores) in 3D CAD data (STEP files) for the SzenoKalk project. You may use, for example, the open-source libraries pythonOCC (OpenCascade for Python), Scikit-Learn or PyTorch. Both rule-based and AI-supported approaches are possible for solving this problem.

You will support us with:

• Development of an algorithm for feature recognition in STEP files
• Use of open-source libraries
• Validation of the approach using specified example components

Ideally, you will have:

• An interest in 3D CAD components and artificial intelligence
• Experience of working with open-source libraries
• Knowledge of Python

Plunge grinding is a high-precision process for machining rotationally symmetric components in hard machining. Newly developed coarse-grained CBN grinding wheels (>300 µm) enable highly productive roughing processes with increased chip volume and can partially replace conventional machining. This makes it possible to shorten process chains, reduce machining times, and lower energy consumption and material usage, which contributes to greater sustainability in manufacturing. At the same time, the demands on process design, tool bonding, and dressing strategies are increasing. The goal is to systematically investigate the process limits as well as the potential for economical and energy-efficient application.

You will support us with:

• Conducting experimental investigations
• Evaluation and analysis of process and test data
• Developing and optimizing experimental setups and dressing processes
• Providing support with presentations and organisational work

Ideally, you will have:

• You have a good command of German
• Independent and structured work is a matter of course to you
• Interest in experimental work is required

As part of the Hannover Digital Innovation Hub, IFW supports small and medium-sized enterprises in leveraging the opportunities offered by digitalization. To achieve this, we develop demonstration systems, organize workshops, support companies in testing and adopting new technologies, and provide up-to-date expertise in areas such as artificial intelligence, digital manufacturing, automation, and data-driven processes. 

You will support us with:

• Development and setup of demonstration systems for trade fairs
• Programming of user interfaces and MCP tools
• Implementation of machine learning models and AI agents
• Analysis of production and energy data

Ideally, you will have:

• You are interested in IIoT protocols, KNIME and n8n
• Basic knowledge of Python and SQL is desirable
• You have strong problem-solving skills
• Independent and structured work is a matter of course to you

In the Optidrap project, we are developing automated draping processes for the production of complex fibre composite components – for example, for innovative aircraft structures. At the heart of the technology is a pneumatically driven, fibre-reinforced elastomer actuator that can take on a variety of shapes, enabling the production of complex geometries. Several of these soft robotics-based elements form a continuum actuator, whose shaping is additionally supported by parallel kinematics. In your work, you will further develop the actuators into a modular and scalable system. Important aspects here are the reproducibility of the mechanical properties and the integration of embedded sensor technology for measuring surface pressures during draping.

You will support us with:

• Literature research, design and construction of a modular elastomer actuator
• Prototype implementation of the elastomer actuator in a coordinated manufacturing process (e.g. casting in 3D-printed molds)
• Experimental characterisation of the properties of the actuator

Ideally, you will have:

• Interest in the fields of soft robotics and embedded sensors
• Experience working with CAD systems
• Knowledge of mechanical or electrical engineering or mechatronics

Components and structures made of carbon fiber reinforced plastic (CFRP) offer enormous lightweight construction potential for aviation due to their low weight and high specific strength. A particularly good ratio of mechanical properties to weight is achieved with sandwich structures. The use of such structures in future aviation applications should make a significant contribution to CO2 savings and thus to meeting climate targets. At the CFRP North Research Center in Stade, the IFW is developing and researching a new production method for manufacturing thermoplastic sandwich structures using automated fiber placement technology.

You will support us with

• thermomechanical process modeling
• experimental process investigation

The type and scope of the work can be determined individually. Experimental parts of the work are to be carried out in Stade, while analysis, evaluation and modeling are independent of location.

In the TowPregRod project, we are developing an automated manufacturing method for the continuous production of CFRP sandwich rods used in the aerospace industry. A prototype of the production system is being set up at our site in Stade for the experimental investigation of the process. You can expect a variety of tasks that can be adapted to your individual interests and knowledge.

You will support us with

• Literature research and designing control and regulation concepts for the manufacturing system
• Programming and implementing control and regulation technology for various assemblies
• Commissioning of the production system and experimental investigation of the production method

As a member of the "SHORELiner" consortium, we are working on a fully electric aircraft. The battery-powered, 10-seat composite aircraft with robust aerodynamic and STOL (Short Take-Off and Landing) capabilities is scheduled to be completed by the end of 2026, contributing to CO₂-neutral mobility of the future. Together with our project partner Broetje-Automation, we are developing a sustainable CFRP manufacturing process for the SHORELiner.

You will support us in:

• Experimental and simulative investigation of CFRP manufacturing processes (including Automated Fiber Placement) for the development and integration of digital process twins
• Development of a dynamic process chain model to reduce energy and resource consumption of the process chain concept
• Selection, implementation, training, and validation of suitable AI models for process chain optimization of fiber-reinforced polymers

We are researching laser-based Automated Fiber Placement, which can be used to process carbon fiber-reinforced thermoplastics. In contrast to the thermosets used in aircraft construction, for example, thermoplastics can be melted and recycled again and again. Our focus is on energy-efficient production strategies, ultra-light sandwich structures and the use of sustainable materials.

You support us with:

• Design and implementation of mechatronic assemblies for the further development of Automated Fiber Placement systems
• Development and implementation of sensor systems for thermal monitoring of the process
• Experimental process analysis and deriving strategies for minimizing energy consumption
• Analytical and numerical modeling of laser-based Automated Fiber Placement

In turning operations of high-strength materials, an infinitely long chip forms unless it is deflected strongly enough to break. If such a long chip occurs, it often cannot be removed easily, endangers the tool, workpiece and machine, and hinders automation. Therefore, we try to predict chip breakage before machining in order to adjust the process planning accordingly.

You will support us with: 

• Implementation of various ML-based and rule-based approaches
• Investigation of the limits and possibilities of these approaches
• Documentation of the models and results

Ideally you have:

• Interest in programming with Python or C#
• Interest in manufacturing processes
• Independent and structured way of working

In SFB 1153, we investigate how turning affects the component lifetime of hybrid components. Turning introduces surface residual stresses into the workpieces, with compressive residual stresses generally extending service life and tensile residual stresses shortening it. The residual stresses depend on the process forces and workpiece temperatures occurring during machining. Therefore, we aim to measure these and correlate them with the resulting residual stresses.

You will support us with: 

• Conducting experiments to measure workpiece temperature and process forces
• Evaluation and interpretation of the results
• Analysis of the relationships between the turning processes and the resulting residual stresses

Ideally you have:

• Interest in manufacturing technology
• Enjoyment of experimental work
• Independent and structured way of working

PVD coatings are critical for the performance of cutting tools. In this project, you will investigate their performance during the turning of C45 heat-treated steel. By varying the coating composition and the cemented carbide substrate, you will analyze their influence on wear behavior.

You will support us with: 

• Conducting experimental investigations
• Analyzing the experimental results
• Documentation of the results

Ideally you have:

• Independent and structured work is a matter of course to you
• Interest in experimental work is required

FE-based wear simulation has great potential for the design of PVD-coated cutting tools. However, its accuracy depends largely on the underlying settings and material models. The goal of this thesis is therefore to systematically analyze the influence of the coating material model on the simulation results.

You will support us with: 

• Conducting experimental investigations
• Conducting FE-Simulations
• Analyzing the experimental results
• Documentation of the results

Ideally you have:

• Independent and structured work is a matter of course to you
• Interest in experimental work is required
• Experience with FE simulations

In the iWearAdapt project, you will contribute to the foundations of AI-supported milling processes. You will investigate a novel approach for determining stability diagrams directly on the machine tool and analyse how different tool wear states affect process stability. The results form an important basis for adaptive, AI-driven process optimisation.

You will support us with:

• Simulation of process stability for AI-supported process models
• Conducting modal analysis and milling experiments
• Processing measurement data and generating stability lobe diagrams
• Developing a wear-dependent stability lobe diagram generator for AI applications

Ideally you have:

• Good knowledge of vibration theory
• Initial experience with MATLAB
• Interest in workshop-based experimental work

This study focuses on the systematic investigation of various heat treatment processes and cooling media, with the aim of specifically increasing the hardness of nickel-free, iron-based alloys. The objective is to develop optimal process conditions for durable, cutting-off tools used in asphalt applications.

You will support us with: 

• Carrying out sintering processes to produce coating test specimens and grinding tools
• Carrying out mechanical tests
• Analysing SEM images and force data

Ideally you have:

• Interest in manufacturing processes
• Attention to detail when conducting experiments

This study focuses on the systematic investigation of various heat treatment processes and cooling media, with the aim of specifically increasing the hardness of nickel-free, iron-based alloys. The objective is to develop optimal process conditions for durable, cutting-off tools used in asphalt applications.

You will support us with: 

• Carrying out sintering processes to produce coating test specimens and grinding tools
• Carrying out mechanical tests
• Analysing SEM images and force data

Ideally you have:

• Interest in manufacturing processes
• Attention to detail when conducting experiments

In the Addi-Randschicht project, we are investigating how an additive-subtractive process chain influences the fatigue life of aluminium components. The aim of your thesis is to develop a 3D finite element simulation model of the deep rolling process. The model is intended to describe the influence of local inhomogeneities on the resulting surface and subsurface properties and thus form the basis for predicting fatigue life.

You will support us with:

• Development, implementation, and evaluation of the simulation
• Transfer of the simulation model to inhomogeneous, additively manufactured materials
• Validation of the simulation using experimentally determined subsurface properties
• Derivation and interpretation of relevant quantities for fatigue life prediction

Ideally you have:

• Interest in production technologyand numerical simulation

• Basic knowledge of structural 3D FE simulation using ANSYS, ABAQUS, or a comparable simulation software

Within a research project on the simulation-based design of coated cutting tools, an FE-based wear model is to be developed. The objective is to describe continuous tool wear in the turning process considering thermomechanical loads and to implement the model into an existing chip formation simulation framework.

You will support us with:

• Literature research on wear models in machining
• Development of an FE-coupled wear model
• Implementation of the model into an existing FE simulation
• Execution and evaluation of selected test simulations

Ideally you have:

• Interest in machining processes and FEM
• Structured and independent working style

In the reFrame project, we are investigating energy-efficient layup strategies in thermoplastic Automated Fibre Placement (TAFP) at the CFK Nord research centre in Stade. To this end, we are analysing the energy consumption of individual machine components while varying key process parameters. The results of your work will thus contribute to reducing energy consumption and CO₂ emissions in automated composite manufacturing.

You will support us with:

• Selecting and implementing suitable energy measurement systems
• Preparing, carrying out and evaluating energy measurements during the TAFP process
• Modelling energy consumption as a function of process variables
• Identifying and investigating optimisation potential for increasing energy efficiency

Ideally you have:

• Basic knowledge of automation or manufacturing technology
• Programming skills (for example, MATLAB or Python)
• High motivation and independent way of working

The nature and scope of the work can be determined individually. Experimental work is to be carried out in Stade, while analysis, evaluation and modelling can be done from any location.

In this project, you will develop a Matlab-based tool for evaluating material removal simulations of continuous generating grinding of cutting tools. You will analyse process-related parameters and determine the spatially resolved load on the grinding wheel. In doing so, you will gain a better understanding of the process and identify potential for optimisation.

You will support us with:

• Execution and evaluation of simulations
• Programming of a Matlab tool for analysing grinding wheel loading
• Analysis and interpretation of process-related parameters

Ideally, you will have:

• Interest in manufacturing technology and simulation-based process analysis
• Experience with Matlabor a comparable programming language
• Knowledge of programming fundamentals

How precisely can a hybrid machining robot manufacture parts? In this project, you will investigate the manufacturing accuracy of the MAGGIE machining robot using a reference component and assess the quality of the machining.

You will support us with:

• Machining a reference component
• Measuring manufacturing accuracy
• Analysing and interpreting results

Ideally, you will have:

• Interest in machine tools, robotics or machining
• Passion for experimental work

In the Optidrap project, we are developing automated draping processes for the production of complex fibre composite components – for example, for innovative aircraft structures. At the heart of the technology is a pneumatically driven, fibre-reinforced elastomer actuator that can take on a variety of shapes, enabling the production of complex geometries. Several of these soft robotics-based elements form a continuum actuator, whose shaping is additionally supported by parallel kinematics. In your work, you will further develop the actuators into a modular and scalable system. Important aspects here are the reproducibility of the mechanical properties and the integration of embedded sensor technology for measuring surface pressures during draping.

You will support us with:

• Literature research, design and construction of a modular elastomer actuator
• Prototype implementation of the elastomer actuator in a coordinated manufacturing process (e.g. casting in 3D-printed molds)
• Experimental characterisation of the properties of the actuator

Ideally, you will have:

• Interest in the fields of soft robotics and embedded sensors
• Experience working with CAD systems
• Knowledge of mechanical or electrical engineering or mechatronics

At the CFK Nord Research Center in Stade, the IFW is developing and researching automated fiber placement technology. Among other things, the use of a laser-based system enables the processing of thermoplastics as a matrix material and thus the additive manufacturing of recyclable structures. A precise understanding of the interaction between material heating and component quality is necessary in order to set up a process that is as energy-efficient as possible.

You support us with:

• Sensor technology for measuring process temperatures

• (Thermal) process modeling

• Experimental process investigation

The type and scope of your work can be determined individually. Experimental parts of the work are to be carried out in Stade, while analysis, evaluation and modeling are independent of location.

Components and structures made of carbon fiber reinforced plastic (CFRP) offer enormous lightweight construction potential for aviation due to their low weight and high specific strength. A particularly good ratio of mechanical properties to weight is achieved with sandwich structures. The use of such structures in future aviation applications should make a significant contribution to CO2 savings and thus to meeting climate targets. At the CFRP North Research Center in Stade, the IFW is developing and researching a new production method for manufacturing thermoplastic sandwich structures using automated fiber placement technology.

You will support us with

• thermomechanical process modeling
• experimental process investigation

The type and scope of the work can be determined individually. Experimental parts of the work are to be carried out in Stade, while analysis, evaluation and modeling are independent of location.

In the TowPregRod project, we are developing an automated manufacturing method for the continuous production of CFRP sandwich rods used in the aerospace industry. A prototype of the production system is being set up at our site in Stade for the experimental investigation of the process. You can expect a variety of tasks that can be adapted to your individual interests and knowledge.

You will support us with

• Literature research and designing control and regulation concepts for the manufacturing system
• Programming and implementing control and regulation technology for various assemblies
• Commissioning of the production system and experimental investigation of the production method

As a member of the "SHORELiner" consortium, we are working on a fully electric aircraft. The battery-powered, 10-seat composite aircraft with robust aerodynamic and STOL (Short Take-Off and Landing) capabilities is scheduled to be completed by the end of 2026, contributing to CO₂-neutral mobility of the future. Together with our project partner Broetje-Automation, we are developing a sustainable CFRP manufacturing process for the SHORELiner.

You will support us in:

• Experimental and simulative investigation of CFRP manufacturing processes (including Automated Fiber Placement) for the development and integration of digital process twins
• Development of a dynamic process chain model to reduce energy and resource consumption of the process chain concept
• Selection, implementation, training, and validation of suitable AI models for process chain optimization of fiber-reinforced polymers

We are researching laser-based Automated Fiber Placement, which can be used to process carbon fiber-reinforced thermoplastics. In contrast to the thermosets used in aircraft construction, for example, thermoplastics can be melted and recycled again and again. Our focus is on energy-efficient production strategies, ultra-light sandwich structures and the use of sustainable materials.

You support us with:

• Design and implementation of mechatronic assemblies for the further development of Automated Fiber Placement systems
• Development and implementation of sensor systems for thermal monitoring of the process
• Experimental process analysis and deriving strategies for minimizing energy consumption
• Analytical and numerical modeling of laser-based Automated Fiber Placement

A novel approach to the manufacture of sensors, actuators and communication infrastructure is based on the combination of ultrasonic levitation and electromagnets. This enables an active, contactless, non-encompassing and medium-free multi-coordinate positioning system. In this thesis, a control structure for multiple degrees of freedom is optimised and evaluated.

You will support us with:

• Designing an optimised control structure using Simulink
• Extending the control algorithm with various observers
• Experimental validation on the existing prototype
• Comparing the control algorithms and evaluating them

Ideally you have:

• Good knowledge of control engineering
• An interest in laboratory work
• Good knowledge of Simulink

Pin-array clamping systems offer the possibility of reversibly moulding and clamping complex geometries, such as those of 3D-printed components. However, this compromises the achievable clamping force. In your project, you will therefore investigate the clamping force of such clamping systems. To this end, you will plan experimental tests on two different clamping systems, carry them out and analyse the results.

You will support us with: 

• Planning the experimental procedure
• Conducting experimental trials on two clamping systems
• Analysing the recorded force-displacement curves

Ideally you have:

• Interest in experimental work
• Basic experience with the design of experiments
• Basic experience with Matlab

The PhoenixD Cluster of Excellence is researching new technologies for manufacturing precision optics. Conventional guidance systems reach their limits when it comes to the precision required. We are therefore developing an innovative electromagnetic precision axis for fine positioning and compensation of trajectory errors. Your task is to design a module unit for combining the sensor and actuator systems, taking thermal and mechanical influences into account.

You will support us with:

• Calculation of the positioning force of the reluctance actuator
• Simulation of electromagnetic behaviour
• Determination of actuator geometry

Ideally you have:

• Interest in mechatronic systems
• Experience working with FEM software (for example, Ansys)
• Affinity for constructive design

The PhoenixD Cluster of Excellence is researching new technologies for manufacturing precision optics. Conventional guidance systems reach their limits when it comes to the precision required. We are therefore developing an innovative electromagnetic precision axis for fine positioning and compensation of trajectory errors. Your task is to design the reluctance actuators, taking into account the installation space geometry and electrical safety.

You will support us with:

• Calculation of the positioning force of the reluctance actuator
• Simulation of electromagnetic behavior
• Determination of actuator geometry

Ideally you have:

• Interest in mechatronic systems
• Experience working with FEM software (for example, Ansys Maxwell or FEMM)
• Knowledge of electromagnetic fields (for example, from the lecture on electrical engineering 2)

Linear guides are a key component in machine tools. They have a significant influence on the accuracy of the machine. Sensorisation of linear guides enables the load to be measured without changing the rigidity and design of the machine axes. Knowledge of the spatially and temporally resolved change in load provides the basis for monitoring machine accuracy.

You will support us with: 

• Conducting tests to measure the smooth running of sensorised linear roller guides
• Evaluating the test results and comparing them with the measured loads

Ideally you have:

• Interest in manufacturing technology and the machines used
• Independent and structured way of working

Would you like to put your know-how into practice and research innovative technologies? Become part of our team and work on these exciting projects, for example: Handle-free guidance, force machine or preload adaptation for ball screw drives. In these projects, you will work with us to develop intelligent machine components - from design and simulation to testing on the test benches and machine tools in our institute's test field. You will gain practical insights into all areas of the engineering profession and have the opportunity to drive forward tomorrow's technologies today.

You will support us with:

• designing and laying out machine components
• sensorisation and experimental characterisation of machine components
• FEM simulation of various components

When trying to achieve the highest possible material removal rates during milling, the limiting factor is often not the power of the machine, but rather the fact that self-excited vibrations occur once a certain depth is reached. As wear icreases, the shape of the milling cutter changes in such a way that it dampens thes vibrations. We investigate the exact mechanisms through analog experiments on our planning test rig and through tests on our milling machines.

You will support us with:

• Conducting experimental investigations
• Evaluation and analysis of process an test data
• Providing support with presentations, organisational work and documentation

Ideally, you will have:

• A good command of german
• Independet and structured work is a matter of course to you
• Intrest in experimental work
• Intrest in machining