Master Thesis: Characterization of the Compressive Behavior of Seal on Bipolar Plate Assemblies for Fuel Cell Stacks

Job Description:

About Aerostack & Project Context

Aerostack, a joint venture between Airbus and ElringKlinger AG, is developing high-performance fuel cell stacks to enable zero-emission commercial flight. A critical challenge in this mission is mastering the complex mechanical interaction between hyperelastic polymer seals and ultra-thin, work-hardened metallic bipolar plates (BPP). We are looking for a master's student to define the exact compression tolerance band that guarantees a perfect seal without crushing the metallic structures.

Project Scope

Your primary objective is to characterize the compression behavior of Seal on Bipolar Plate (SoBPP) assemblies and define a safe operating window that directly contributes to a weight-optimized aerospace fuel cell stack.

Key Responsibilities & Tasks

Experimental Characterization:Conduct mechanical compression tests on representative SoBPP assemblies to measure force-displacement responses and identify the onset of localized plastic deformation.

State-of-the-Art Research:Review current literature on the compression behavior of thin metal-polymer assemblies to support your methodology.

Data Synthesis:Define the allowable compression window by identifying exact failure thresholds for both under-compression (leakage) and over-compression (structural collapse).

Hardware Optimization:Translate your experimental findings into actionable design guidelines to minimize the weight of the fuel cell stack compression system.

Start date: November 2026

Location: Aerostack GmbH, Dettingen an der Erms, Germany

Duration: 6 months

Profile & Qualification

Required skills & background

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, Computational Engineering, or a comparable field of study

• Software and Tools:

  • Solid knowledge of structural mechanics and materials science

  • Initial experience with computer-aided design (CAD) and finite element (FE) modeling

  • Basic programming skills (e.g., Python)

  • Hands-on laboratory experience

• Mindset and Languages:

  • Independent and structured way of working

  • Language Skills: Fluent in English

General information

Our offer

• Challenging tasks driven by unique products and cutting-edge technologies

• A welcoming and collaborative atmosphere in a professional, international environment

• Comprehensive onboarding program to ensure a smooth start

• Monthly compensation

• Flexible working hours

• On-site catering facilities

Comments

• Candidates need to be enrolled at ideally a German or European university

• Candidates are responsible for independently securing an academic supervisor at their university

• Note that this position requires a 5-day on-site presence and no assistance for finding accommodation can be provided

Application

We look forward to receiving your application, including your CV, cover letter, current transcript of records, certificate of enrollment, your intended institute, and your earliest possible start date via the tool andemail:

[email protected].

Please use the subject line ‘Application Master Thesis: SoBPP Compression / [Your Name]’; otherwise, your application cannot be processed or considered.

For technical questions or further details regarding the scope of the thesis, please feel free to reach out to:

Dr.-Ing. Felix Weber

Simulation Engineer

E-Mail: [email protected]

This job requires an awareness of any potential compliance risks and a commitment to act with integrity, as the foundation for the Company’s success, reputation and sustainable growth.

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