3D Printing & Lightweight Design Engineer

3/2020 – 2/2021

Master thesis in cooperation with Airbus Operations GmbH. (Grade 1.0)

Topic: Distortion reducing investigations in Wire Arc Additive Manufacturing (WAAM) process to reinforce aerospace fuselage shells.

Back in early 2021 I have submitted my master’s thesis, which I have done for Airbus at the Welding Engineering Research Centre as part of the Cranfield University in England. Airbus created various design concepts of topology optimized stiffener structures as part of the whole fuselage. Especially in the fuselage shell, in terms of replacing conventional casted and riveted/welded stiffener structures with an enhanced structural topology optimized design regarding to the acting force flow. This form lightweight construction strategy will lead to significant weight savings in the airplane. However, for this innovative lightweight approach, it is necessary to find a suitable manufacturing process to manage challenges of arising distortions during the deposition of structures on thin aluminum sheet components.

After research investigations as part of my bachelor thesis resulting in the manufacturing of an aluminum demonstrator, I have examined the possibilities of the WAAM process in the same scope. Thus, I have examined distortion reducing investigations as induced thermal residual stresses will result in high deformations on thin aluminum sheet components.

First, I created a simulation model approach of the WAAM process to predict buckling distortion including experimental calibrations. Furthermore, the practical experiments consisting out of parameter optimization for a low heat input and distortion reducing methods such as compliant tooling, pre-heating and various manufacturing strategies. Thereby, the Cold Metal Transfer process was used within the WAAM experimental set up to produce a demonstrator for comparison with the manufactured demonstrator result out of my bachelor’s thesis.

3D Rekonstruktion, Lasermaterialbearbeitung, Laserschweißen, Leichtbau, Metallschutzgasschweißen (MSG), Metallschweißen mit inerten Gasen (MIG), Metallografie, Metallurgie, Industrielle Roboter, Robotik / Robotertechnik, 3D-CAD

8/2017 – 2/2018

Bachelor thesis in cooperation with Fraunhofer IAPT. (Grade 1.0)

Topic: Reduction of distortion during Laser Metal Deposition (LMD) of bionic stiffener structures on thin aluminum aerospace sheets.

Back in early 2018 I have submitted my bachelor’s thesis, which I have done for Airbus at the Fraunhofer IAPT in Hamburg. The aim was to produce bionic lightweight structures in aircraft fuselages using Additive Manufacturing processes, which are in public better known as 3D Printing processes. Thereby, the idea was to replace conventional stringer-frame structures of the fuselage with topology optimized stiffener structures to save weight in order to reduce CO2 emissions. After conducted process parameter optimizations to reduce the thermal input, it was possible to produce a demonstrator containing a 1000 x 500 x 4 mm plate reinforced with a 3.7 mm high bionic lightweight structure.

In my bachelor’s research for Airbus, I have used the Directed Energy Deposition process in terms of LMD. Back in 2018, it was an important input for Airbus to get more insights into the challenges and possibilities of robot-based and large-scale Additive Manufacturing. If you like to get some more detailed information about this topic, please check out the Scopus listed and peer-reviewed paper in my LinkedIn “publications” section.

As part of my following master’s thesis in 2020 I have used the Wire Arc Additive Manufacturing (WAAM) process for further investigations. Due to the fact, that the used LMD process is unsuitable for applying stiffener structures on thin aluminum plates, it makes more sense to use the WAAM method with higher deposition rates and lower energy input.

Produktdesign, 3D Rekonstruktion, Aluminothermisches Schweißen, Lasermaterialbearbeitung, Leichtbau, Metallschweißen mit inerten Gasen (MIG), Flugzeugbau, Luft- und Raumfahrttechnik (allg.), Metallografie, Metallurgie, Industrielle Roboter, Robotik / Robotertechnik, 3D-CAD, Drucktechnik

12/2016 – 5/2017

Analysis of fibre-reinforced plastics and innovative applications such as additive manufacturing methods, bionic lightweight designs and self-healing materials in the automotive chassis. (Grade: 1.3)

Produktdesign, Forschung & Entwicklung (allg.), Ingenieurwissenschaft, Datenbankrecherche - Patentrecherchen, Automobil-Leichtbau, Leichtbau