Goal:
The goal of this thesis is to review and optimize the design of a complex component of the flight control system, as of today manufactured from different sheet metal parts joined together by several welding operations, for manufacturing by means of metal additive manufacturing (AM). Besides restrictions specific to the AM process, relevant constraints have to be taken into account based on the exemplary H145 helicopter.
The ambition of this thesis is to obtain a design sufficiently mature for the manufacturing and testing of prototype parts; the scope of this thesis includes the following tasks:
- research and analysis of state-of-the-art concepts for complex and highly integral parts manufactured by means of metal additive manufacturing;
- specification of all requirements and constraints for the selected component of the flight control system; special focus on requirements and constraints for metal additive manufacturing;
- collection of all relevant loads (static and dynamic loads) acting on the selected component of the flight control system; determination of the most relevant load cases for sizing of the component;
- development of a new design / new designs for the selected component of the flight control system for metal additive manufacturing with special focus on design solutions with few internal interfaces / joints; selection of most promising design(s);
- Design, optimization and substantiation (static strength and fatigue strength) of most promising design(s) for the selected component of the flight control system by means of
- analytical analysis
- numerical analysis and optimization based on detailed and validated FEM models;
- Evaluation of most promising design(s) for the selected component of the flight control system with regard to
- Mass
- Costs (recurring costs, non-recurring costs, etc.)
- Inspection needs and fatigue lifetime;
- documentation of all investigations, analysis results including an evaluation/outlook with regard to future projects and developments.
Skills & Tools:
High motivation and the ability to work independently; first experiences in FEM and part design for additive manufacturing (AM) is an advantage but not mandatory; excellent interpersonal and communication skills.
Experience with CATIA and ALTAIR HyperWorks suite is a plus but not mandatory.
Language: German or English
Location: Donauwörth
Start: January 2026 (or later)
Duration: 6 months
Kontaktperson:
Thomas Pfaffinger - Stress Engineer
Leonhard Mitterleitner - MPM Rotor Stress & Squad Leader
