The vision of the DLR Institute of Future Fuels is to develop technological solutions that enable the cost-effective production of sustainable fuels and chemical commodities in the sunbelt of the earth on an industrial scale. At the institute, we use our unique infrastructure in which concentrated solar energy covers the heat demand of high-temperature processes. An important part of our work is researching and testing new materials, processes and technologies on a laboratory and pilot scale, to this end, we utilise a modern infrastructure of laboratories and large-scale facilities.
What to expect
In the Department of Solar Chemical Process Development, we are jointly researching innovative materials, processes and reactors that make it possible to produce fuels using renewable energies. One of our ongoing efforts focuses on the development and optimization of ceramic foams and porous structures that serve as functional materials in thermal applications.
This Master’s thesis project involves the design, development, and experimental validation of a semi- or fully-automatic system for dip-coating polymeric foam templates used in the replica method for manufacturing Reticulated Porous Ceramics (RPC). You will be actively involved in the entire experimental workflow – ranging from solution preparation and testing on the new system to the detailed characterization of the resulting RPC structures.
This project offers an excellent opportunity to gain valuable hands-on experience in CAD, automation, and ceramic processing. The skills acquired in the process are highly relevant – both for an academic career in research and for professional opportunities in the materials and process engineering industry.
Your tasks
- design and development of an automated machine for the controlled application of coating layer and/or removal of excess ceramic coating from polymeric foam templates
- conduct a literature review on ceramic foam fabrication, coating technologies, and techniques for achieving homogeneous coating application
- perform experimental trials to optimize the machine’s performance and process parameters
- characterize coated samples before and after sintering for coating thickness, uniformity, open pore structure, and mechanical properties
- analyze process variables affecting excess coating removal efficiency, coating consistency, and repeatability
- document and present experimental results, including data analysis and interpretation
Your profile
- enrolled in a Master’s program in Mechanical Engineering, Mechatronics, or a related field
- demonstrated interest or experience in mechanical design, prototyping, or automation systems
- experience with CAD software, particularly Autodesk Inventor, for mechanical design and assembly modeling
- programming experience in LabVIEW Python and MATLAB for data analysis, control systems, or automation
- interest in or exposure to AI tools or methods for process optimization, data interpretation or experimental design
- self-motivated, hands-on, and capable of working independently as well as part of a team
- good communication skills in English for documentation and presentation of results
Remuneration is up to the German TVöD depending on qualifications and assigned tasks.
We look forward to getting to know you!
If you have any questions about this position (Vacancy-ID 2647) please contact:
Fabio Pierno
Tel.: +49 2203 601 1167
