FEM Simulation of the Thermomechanical Stress in Additively Manufactured Ceramic Nozzles
Ceramic nozzles capable of withstanding high thermal and mechanical stresses are required for the gas atomization of metals. Additive manufacturing using vat-photopolymerization (VPP) is intended to optimize these nozzles to increase their durability and efficiency. During operation, repeated heating and cooling cycles generate thermomechanical stresses that can peak at geometric transitions. This project develops a finite element (FEM) model of the nozzle geometry to simulate these stresses. Various porosity conditions are then introduced to examine their influence on the stress field and potential critical areas. The goal is a functional FEM model and an initial assessment of how porosity affects critical stress areas.
Institute: wbk
Prerequisites: none

Design and construction of an experimental setup for measuring residual stresses in thin films from -50°C to 100°C using the substrate curvature method
The aim is to design a system for measuring layer stresses and design it so that it is ready to order. Students apply fundamental knowledge of materials mechanics, optics, thermodynamics, and diffusion to develop a novel measuring instrument. Successful communication within the team and with companies is central for the project. Task: • Design of a laser-based wafer curvature system • Sample 30x10mm² • Thickness 100µm-300µm • Layer thickness 20µm • Design of heating/cooling chamber • Cooling with liquid nitrogen • Temperature setting from -50°C to 100°C • Design of the chamber window • Prevention of condensation • Design of the instrument using underlying physics • Production drawings • Request for quotation
Institute: IAM-MMI
Prerequisites: none

Automated mapping of surface topographies via LabVIEW
To analyze component residual stresses using the contour-method, EDM-generated cross sectional surfaces must be measured with high precision using a predefined measurement grid. The large number of measurement points must then be smoothed and fed into a FEM-routine for stress calculation. We are developing a system, in which the topography of the cross-sectional surface will be automatically measured using a laser-distance-sensor. The scanning will be performed using an x-y-linear-stage. A LabVIEW-based control routine must be developed for this setup. Control and data acquisition will be managed via an intuitive GUI. The project aims to commission the device incl. LabView control and conduct initial real experiments.
Institute: IAM-WK
Prerequisites: Experience with LabVIEW is an advantage but not required.

Investigation of the thermal behavior of battery cells with three different cell chemistries during charging and discharging
The heat generation during charging and discharging of battery cells plays a crucial role in determining safe charging rates in many applications Therefore, the heat generation needs to be measured. This project investigates the heat generation of battery cells based on three different chemistries: lithium iron phosphate (LFP), nickel cobalt aluminum (NCA) and sodium-ion cells. Measurements will be conducted using a Tian-Calvet-calorimeter. The cells will be electrochemically characterized before and while the cyclic aging. The heat generation during charge and discharge will be measured regularly and correlated with electrochemical data to identify the link between cell aging and thermal behavior.
Institute: IAM-AWP
Prerequisites: none

Influence of Zr on the Oxidation Behavior of a Cr-Mo-Si alloy
Climate change and the resulting need for an energy transition present us with the major challenge of improving the efficiency of existing systems, which are based on the combustion of fossil fuels and cannot be replaced by electric systems in the foreseeable future. One promising solution is novel high-melting-point refractory metal alloys, which can increase combustion temperatures in gas turbines and prevent efficiency losses caused by cooling engine components. However, a common drawback of these alloys is their insufficient oxidation resistance at very high temperatures. This project aims to investigate the oxidation properties of a novel Cr-Mo-Si-Zr alloy at 1200°C.
Institute: IAM-WK
Prerequisites: none

Simulation of heat transfer during fluid flow in fractures
Heat transport and transfer for fluid flow through fractures geothermal reservoirs is important for the efficiency assessment and optimisation of geothermal energy extraction systems. The fracture geometry, flow and thermal conditions influence how effectively heat is transferred from the rock to the fluid, thereby affecting the system efficiency. Numerical simulations help to understand and predict these transport processes. Simulation studies for different fracture geometries and with varying parameters, e.g. different flowrates, are used for this purpose. The task involves generating realistic fracture geometries, conducting simulation studies with flow and heat transfer under different conditions, and subsequent evaluation of the results.
Institute: IAM-MMS
Prerequisites: Stoff- Wärmetransport, Strömungsdynamik

Numerical simulation of the coupled temperature and crystallization evolution in thermoplastics
The manufacturing of thermoplastics involves heat transfer, which strongly affects crystallization. Since crystallization is exothermic, the released heat must be included in a simulation model. One approach is to model the heat-source term in the heat equation as dependent on crystallization and cooling rates. The Nakamura model can describe the time evolution of the degree of crystallinity. This project focuses on implementing a Python numerical solver that accounts for the coupled evolution of temperature and crystallinity. The solver will operate on a two-dimensional domain. Sensitivity studies will be performed based on this solver.
Institute: IAM-MMS
Prerequisites: Technische Mechanik, Interesse an Programmieren

There are currently no projects offered in this area in english language.

Characterization of a Scale-Model Wind Tunnel
A few years ago, a scale model of the institute's large wind tunnel was built at the Institute of Fluid Mechanics. The objective of this project is to experimentally characterize the flow within this model tunnel using pressure measurement techniques. The students determine the distribution of dynamic and static pressure inside the wind tunnel test chamber. For this purpose, the measurement volume is systematically traversed using a Prandtl tube to record time-resolved pressure data across various locations. Data acquisition is done via digital pressure measurement systems and computer based. Finally, the recorded time series are analyzed using appropriate statistical methods and clearly visualized.
Institute: ISTM
Prerequisites: Abschluss der Lehrveranstaltung 'Strömungslehre'

There are currently no projects offered in this area.

Generating Parametric CAD Models with Natural-Language Prompts
At the Chair of Data Science in Mechanical Engineering one of our research areas is centered around generative methods for CAD. In Team Work you will develop a dataset linking parametric CAD models with natural-language prompts that describe them at different levels of detail and granularity. You will define model categories, generate or collect CAD geometries, and create consistent prompt annotations ranging from broad shape descriptions to detailed geometric and parametric specifications. You will also develop a tool for comparing and matching geometries, enabling generated models to be evaluated against reference designs. Finally, you will investigate how large language models can translate the prompts into executable CadQuery code and assess how reliably the resulting code reproduces the intended CAD models.
Institute: IMI
Prerequisites: none

Development of an Autonomous Throwing and Return Robot
You will work in a team in the Machine Intelligence and Robotics Lab to develop a robotic system that autonomously throws and retrieves an object in a continuous cycle. Using an existing robot arm, you will design and build a return mechanism that guides the thrown object back to the robot. The mechanism will be designed in Autodesk Fusion and fabricated using 3D printing or other methods. It should be mobile and modular, allowing later extensions. Then you will program the robot to throw in the return mechanism, integrate the system, evaluate its performance through testing and repeated throwing cycles.
Institute: IMI
Prerequisites: none

Lidar-based traffic counting
In this project, a supervised student group develops a privacy-protected traffic participants counting pipeline. The sensor input to the pipeline is a LiDAR. The processing steps and subtasks include point cloud segmentation of static versus dynamic objects / definition, retrieval and classification of dynamic traffic participants / visualization and presentation of the results. The sensor framework is ROS2 students will write their code in Python. The focus is on non-neural algorithms. Documentation and milestones are organized as in a professional project and prepare students for their Bachelor’s thesis. The project is hosted at the Institute of Measurement and Control Systems.
Institute: MRT
Prerequisites: programming experience, at best in python

Robotic Disassembly of Elastic Components
This project investigates the robotic disassembly of elastic and compliant components. The aim is to enable a robot to reliably remove elastic or deformable components from assemblies. Suitable grasping strategies, motion sequences, and disassembly processes will be developed and experimentally evaluated. Particular attention will be paid to the interaction between the robot, the component, and the surrounding assembly, as well as to the deformation of components during the disassembly process. The developed approaches will be evaluated using selected components and assessed with regard to their robustness and transferability to different disassembly tasks.
Institute: wbk
Prerequisites: Python und numerische Programme (z.B. MATLAB), Robotikkenntnisse allgemein

Applied AI in Robotics: Teaching a Robot to Walk and Manipulate
You will work in a team in the Machine Intelligence and Robotics Lab to teach a quadruped robot (ANYmal D) with a 6-DoF robotic arm to walk and manipulate simultaneously. Using Reinforcement Learning in NVIDIA Isaac Lab, you will train the robot to follow a desired walking velocity while keeping its arm on a defined trajectory. The main challenge is balancing both behaviours while respecting the robot’s kinematic and dynamic limits. You will design and tune reward functions, investigate their effects on locomotion and manipulation, document your findings, and evaluate the resulting behaviour under different trajectories and conditions in simulation.
Institute: IMI
Prerequisites: none

There are currently no projects offered in this area.

Analysis of Eye-Tracking Data from Remanufacturing and Contextualizing it with Lab Data
As part of the SFB 1574 Circular Factory, we investigate the implicit knowledge of experienced operators during manual disassembly processes. A real-world industrial dataset from a remanufacturing industry partner is available for this project. The focus lies on the analysis of industrial gaze data and its integration with questionnaire data. The objective is to model cognitive decision-making processes when dealing with unforeseen component conditions on the shop floor. By systematically contrasting this field data with existing laboratory experiments, the project bridges the gap between controlled laboratory conditions and complex industrial applications. Further targeted data collection in the field is possible.
Institute: ifab
Prerequisites: Erfahrung im empirischen Arbeiten von Vorteil, Erfahrung mit Eye-Tracking Daten von Vorteil

Design and Integration of an Inductive Sensor System for Position Determination of Skived Gears
For the post-processing of gears manufactured using gear skiving, the exact position of these gears must be determined. Various types of sensors, such as tactile, inductive, or optical measurement systems, can be used for this purpose. First a review of existing concepts for calibrating gears are evaluated. Building on this, an installation space assessment will be conducted, and a suitable mounting bracket for an inductive sensor will be designed. The sensor system will be installed inside the machine and commissioned. The position of the gears will be determined using the newly integrated sensor system, enabling reliable position determination for post-processing.
Institute: wbk
Prerequisites: none

Machine learning-based wear detection for used angle grinders in the circular factory
At Kreislauffabrik, functional testing prior to dismantling is crucial for objectively assessing the condition of a product and making informed decisions about the next steps in remanufacturing. An angle grinder serves as a demonstration model, in which defects and wear are revealed through vibration time series, audio signals (microphone) and test bench parameters such as power and current consumption. The aim of this work is to develop an AI-supported, multimodal evaluation system that records these signals in synchronisation, analyses them automatically and detects anomalies/defects from them – ideally including an initial hypothesis as to which type of fault is likely to be present. To this end, you will develop a test programme with reproducible test procedures and measurement sequences, introduce defects in a targeted manner (fault injection), perform the experiments and utilise data fusion and machine learning to identify robust patterns in the time and frequency domains. The project combines sensor technology, signal processing, automation and applied AI on a real-world test bench.
Institute: wbk
Prerequisites: none

Development of a Multi-Sensor Measurement Database and Live Visualization for Process State Analysis in Turning under Industrial Disturbance Conditions
This project combines classic mechanical engineering with intelligent data processing in the context of Industry 4.0. The focus lies on the systematic planning and execution of turning tests on an industrial lathe to investigate critical process states such as tool breakage or varying cutting conditions. You will build a structured measurement database based on force, spindle current, structure-borne sound, and airborne sound sensors, calculate characteristic signal features such as RMS, and develop an interactive live dashboard for signal visualization. Your results will form the direct foundation for AI-based monitoring systems in production. Through this project, you will acquire solid practical skills in modern sensor technology, experimental design, and data analysis, ideally preparing you for your ongoing engineering studies.
Institute: wbk
Prerequisites: none

There are currently no projects offered in this area.

There are currently no projects offered in this area.

Investigation of Traffic Flows at Campus North and Development of an Operating Concept for Integrating a Highly Automated System into Karlsruhe's Rail Passenger Transport System
As part of a current research project, the long-term goal is to create a highly automated rail connection between the North Campus and the current local rail network in Karlsruhe. The students are conducting their own traffic surveys of various modes of transport, analysing real traffic flows and identifying peak times. Based on the data collected, existing line structures are evaluated, operational constraints are derived and a possible integration concept is developed. The result is a concept proposal that shows how an automated railway can be sensibly integrated into the existing transport system (e.g. fixed timetables, demand-oriented services).
Institute: FAST-BST
Prerequisites: none

Day-Ahead Electricity Price Forecasting with Machine Learning
Using hourly German power market data, a machine-learning model is to be developed that forecasts the day-ahead electricity price 24 hours in advance. Training is performed on historical data, while evaluation is carried out on a later, unseen period using a strict temporal split (no shuffling). Only features known at forecast time may be used — calendar variables, price lags, and wind/solar forecasts. Actual load and generation are forbidden (data leakage). The model is to be compared against two baselines (persistence and seasonal-naïve) using MAE (mean absolute error) or RMSE (root mean square error)) the skill score relative to each baseline must be reported. Which features matter most and where the model fails is to be discussed.
Institute: IATF
Prerequisites: Grundkenntnisse in Python wünschenswert

Simulation-Based Design of a PCM Thermal Energy Storage System Via a Reduced Thermodynamic Model
The aim of this project is to develop a reduced thermodynamic model for the simulation-based thermal design of a latent phase-change material (PCM) thermal energy storage system for heat pump systems in single-family homes. Using the model, the influence of different storage volumes and geometries on the transient charging and discharging behavior will be investigated. Considering dynamic building and thermal loads, a suitable storage design will be determined that enables efficient utilization of PV energy while simultaneously reducing thermal peak loads and the grid electricity demand of the heat pump.
Institute: ITT
Prerequisites: Technische Thermodynamik 1, Technische Thermodynamik 2

There are currently no projects offered in this area in english language.

Development of a Control System for a Quadrocopter
Electrically powered multicopters are considered sustainable means of transport because they can operate with zero local emissions. Precise control of the propulsion system is required for energy-efficient and safe operation. To ensure this, this project aims to further develop the control system of an existing drone. To this end, a suitable substitute model will first be identified in order to theoretically derive the relevant control parameters. These parameters will then be implemented in the drone’s control system and validated experimentally. The goal is to achieve the most stable control possible for at least one of the drone’s axes of rotation.
Institute: ITS
Prerequisites: Vorlesung 'Mess- und Regelungstechnik' / Lecture 'Measurement and Control Systems'

Experimental Investigations of Elastocaloric Cooling with Polymer Films
Cooling represents one of the largest global energy demands, and alternative technologies without harmful refrigerants are urgently needed. Elastocaloric cooling uses solid materials that heat up and cool down when mechanically loaded and unloaded. Polymer films are particularly attractive because they are low-cost and can provide large temperature changes. In this experimental project, the student will build and test a small-scale elastocaloric cooling demonstrator using polymer foils. The work includes preparing polymer foil samples, assembling a simple mechanical loading setup, and measuring temperature changes during cyclic loading using thermal sensors or infrared imaging. The student will experimentally investigate how different loading conditions influence the cooling performance of the polymer. The project focuses on hands-on laboratory work, including experimental measurements and analysis of the cooling performance using available laboratory infrastructure.
Institute: IMT
Prerequisites: none