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Master´s student (f/m/d) Design of a Smart Roller for High-temperature Thermoplastic AFP
Job Description
Req ID:  3425
Place of work:  Stuttgart
Starting date:  01.04.2026
Career level:  Student research project and final thesis
Type of employment:  Part time, Full-time
Duration of contract:  30.09.2026

Remuneration: Remuneration is in accordance with the Collective Agreement for the Public Sector - Federal Government (TVöD-Bund)

Enter the fascinating world of the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt e. V.; DLR) and help shape the future through research and innovation! We offer an exciting and inspiring working environment driven by the expertise and curiosity of our 11,000 employees from 100 nations and our unique infrastructure. Together, we develop sustainable technologies and thus contribute to finding solutions to global challenges. Would you like to join us in addressing this major future challenge? Then this is your place!

 

 

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.

 

What to expect

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 work is a cooperation between DLR and UBC and includes a temporary stay in Vancouver, Canada.

 

Your objectives

  • 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

 

Your profile

  • Student (f/m/d) in the field of materials science, aerospace engineering, mechanical engineering or a comparable engineering degree program
  • Fluent English

We offer

DLR stands for diversity, appreciation and equality for all people. We promote independent work and the individual development of our employees both personally and professionally. To this end, we offer numerous training and development opportunities. Equal opportunities are of particular importance to us, which is why we want to increase the proportion of women in science and management in particular. Applicants with severe disabilities will be given preference if they are qualified.

 

 

We look forward to getting to know you!

 

If you have any questions about this position (Vacancy-ID 3425) please contact:

 

Sebastian Nowotny 
Tel.: +49 711 6862 8001 

 
Apply now