Master Thesis – Compressible Seal Behavior for Fuel Cell Bipolar Plates

About the role

Aerostack, a joint venture between Airbus and ElringKlinger AG, is developing high‑performance fuel cell stacks for zero‑emission commercial flight. The role is a master‑thesis project to characterize the compression behavior of seal‑on‑bipolar‑plate assemblies and define a safe operating window.

Key responsibilities

• Conduct mechanical compression tests on representative SoBPP assemblies to measure force‑displacement responses and identify the onset of localized plastic deformation.
• Review current literature on the compression behavior of thin metal‑polymer assemblies to support the methodology.
• Define the allowable compression window by identifying failure thresholds for under‑compression (leakage) and over‑compression (structural collapse).
• Translate experimental findings into design guidelines to minimise the weight of the fuel‑cell stack compression system.

Required profile

• Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Computational Engineering or a comparable field.
• Solid knowledge of structural mechanics and materials science.
• Basic programming skills (e.g., Python).
• Hands‑on laboratory experience.
• Independent and structured way of working.
• Fluent in English.
• Enrolled at a German or European university and able to secure an academic supervisor.

Required skills

• Structural mechanics
• Materials science
• Computer‑aided design (CAD)
• Finite element modeling
• Python programming

What we offer

• Challenging tasks driven by unique products and cutting‑edge technologies.
• Collaborative international environment.
• Comprehensive onboarding program.
• Monthly compensation.
• Flexible working hours.
• On‑site catering facilities.