Adherence to geometric tolerances is essential to the performance and reliability of aerospace components. In milling, these tolerances are influenced by process parameters such as spindle speed or tool selection. You will therefore investigate the influence of different process parameters, measure the resulting workpieces, and finally evaluate your experimental results.

You will support us with:

• Conducting milling experiments
• Performing metrological measurements of workpieces and tools
• Preparing measurement and process data
• Analysing relationships between parameters, tool condition, and form deviations

Ideally you have:

• Interest in manufacturing technology and process analysis
• Initial experience in data preparation and analysis
• An independent and structured way of working

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