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 and email:

felix.fe.weber@airbus.com.

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: felix.fe.weber@airbus.com

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.

Company: Aerostack GmbH

Employment Type: Final-year Thesis

Experience Level: Student

Job Family: Support to Management <JF-FA-ES>

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