Course paper / final thesis, Internship

Material and process modeling for a hybrid application of additive and conventional manufacturing

Starting date

1 September 2018

Duration of contract

6-12 months

Type of employment


"Cutting-edge research requires excellent minds – particularly more females – at all levels. Launch your mission with us and send in your application now!" Prof. Pascale Ehrenfreund - Chair of the DLR Executive Board

Your mission:

Additive Manufacturing (AM) allows decreasing production time and overall cost for building variable and lightweight vehicle structures. Using AM, almost any complex geometry can be processed. This opens up a vast freedom for the design of lightweight structures and components. In order to develop the technology for producing these structures and overcome challenges forseen in materials, process parameters, design methodologies and testing approaches, the University of British Columbia (UBC) in Canada and the DLR in Germany have joined forces into an international collaborative research project.

The UBC Department of Materials Engineering and the DLR Institute of Vehicle Concepts will examine hybrid structure manufacturing approaches through the combination of additive and conventional manufacturing of metal components. An AM process employing Electron Beam Welding (EBW) provides the technological scope to build hybrid structures through combining cast components with additively manufactured joints and local reinforcements e.g. ribs and patches.

DLR Institute of Vehicle Concepts

The institute addresses the development of future technology systems for sustainable, safe, and affordable generations of vehicles on road and rail. The institute's contributions range from conception and design through construction, calculation, and simulation to the presentation of research demonstrators, components, and vehicles.

UBC Department of Materials Engineering

The Department of Materials Engineering is internationally recognized for their expertise in materials and manufacturing. They bring a broad expertise in materials synthesis, characterization and simulation to the field of additive manufacturing. Further, UBC’s facilities comprise several state-of-the-art research benches to conduct and verify among others large-scale experiments, manufacturing processes, and material characterization.


The focus of this work is to develop a process specific material testing and modeling approach for welded joints and structural elements created by EBW on cast aluminum members. Variations of member geometries, material and process parameters have to be produced, identified and evaluated in order to determine suitable parameter sets for automotive load bearing structures.


  • literature review on the current state of the art in material and process modeling of additively manufactured aluminum-structures and hybrid process applications
  • design of experiments focused analysis on process parameters of the EBW process (e.g. material feed, energy/heat input, etc.)
  • mechanical testing of welded members and additively manufactured reinforcements (static/dynamic)
  • evaluation of the correlation between the chosen process parameters and mechanical properties
  • verification of the developed process and material model based on a generic member geometry

Your qualifications:

  • Technical/scientific studies (e.g. Computational Mechanics, Mechanical Engineering, Material Science, etc.)
  • experienced in mechanical testing of materials, material modeling and FE simulation
  • interest in metal-based Additive Manufacturing (3D Printing), Electron Beam Welding (EBW)

Your benefits:

Look forward to a fulfilling job with an employer who appreciates your commitment and supports your personal and professional development. Our unique infrastructure offers you a working environment in which you have unparalled scope to develop your creative ideas and accomplish your professional objectives. Our human resources policy puts great value on a healthy work-life balance as well as equal opportunities for men and women. Individuals with disabilities will be given preferential consideration in the event their qualifications are equivalent to those of other candidates.

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