Job Description:

In order to support the Rotor System Stress department Airbus Helicopters is looking for a

Master Thesis on Design and Optimization of a complex component of the Flight Control System for Additive Manufacturing from metallic materials (d/f/m)

Are you looking for a master thesis at Airbus Helicopters Would you like to work on an innovative design for additive manufacturing for a complex and highly loaded part of a helicopter

Then apply now! We look forward to you supporting us in the Rotor System Stress department!

• Location: Donauwörth
• Start: January 2026 (or later)
• Duration: 6 months

We offer you a challenging task in a multi-national environment with great insights into our products systems and organization.

The Rotor System Stress department is an international team of passionate engineers located on three sites in Germany and France and working on the strength analysis of parts of the dynamic system of a helicopter including main and tail rotor system flight control system and engine and gear box suspension systems.
This Master thesis explores the design and sizing of a complex component of the flight control system as of today manufactured from different sheet metal parts joined together by several welding operations for manufacturing by means of metal additive manufacturing (AM). The ambition of this thesis is to develop a design for metal additive manufacturing with few internal interfaces and/or joints taking into account the specific requirements for AM and all constraints based on the exemplary H145 helicopter. Target is to have a design sufficiently mature for the manufacturing and testing of prototype parts at the end of this thesis.

Your location
At our Donauwörth site located on the banks of the river Danube we develop helicopters from the initial idea to the airworthy product. Watch them take off and touch down on our own on-site test airfield.

Your benefits

• attractive salary and work-life balance with a 35-hour week (flextime)

• international environment with the opportunity to network globally

• work with modern / diversified technologies

• at Airbus we see you as a valuable team member and you are not hired to brew coffee instead you are in close contact with the interfaces and are part of our regular team meetings

• opportunity to participate in the Generation Airbus Community to expand your own network

Your tasks and responsibilities

• research and analysis of state-of-the-art concepts for complex and highly integral parts manufactured by means of metal additive manufacturing

• specification of all requirements constraints and loads (static/dynamic) for the selected component of the flight control system based on the reference helicopter H145; special focus on requirements and constraints for metal additive manufacturing

• development of a new design / new designs for the selected component of the flight control system for metal additive manufacturing with special focus on design solutions with few internal interfaces / joints

• sizing optimization and substantiation (static strength and fatigue strength) of the most promising design(s) for the selected component of the flight control system by means of analytical analysis numerical analysis and optimization based on detailed and validated FEM models

• evaluation of the most promising design(s) for the selected component of the flight control system with regard to mass costs inspection needs and fatigue lifetime

• documentation of all investigations and analysis results including an evaluation/outlook with regard to future projects and developments

Desired skills and qualifications

• enrolled as full-time aerospace engineering or mechanical engineering student (m/f/d) or similar field of study

• interest and first experience in sizing and optimization of mechanical parts

• structured independent and proactive way of working / high motivation / team spirit

• design skills (CATIA suite) and finite element method modelling skills (Altair Hyperworks suite ) are a plus

• knowledge of additive manufacturing process is a plus

• language skills: advanced in German and English

Please upload the following documents: cover letter CV relevant transcripts enrolment certificate.

Please upload the following documents: cover letter CV relevant transcripts enrollment certificate.

Not a 100% match No worries! Airbus supports your personal growth.

Take your career to a new level and apply online now!

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

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