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Student paper

Geometry optimization in lightweight structural design

Research laboratory or project work

In your thesis, you will investigate the influence of plasticization on fiber length reduction during foam injection molding with the ProFoam lock.

The established special process of thermoplastic foam injection molding offers various advantages over conventional injection molding. Foam injection molding reduces shear during plasticization, resulting in longer fibres and better mechanical properties. In addition to the fiber length, the fiber orientation is also decisive for the mechanical properties, which is why this must be controlled when designing the molded part. There are currently no design specifications for the design of foamed long-fiber-reinforced molded parts. The first step is therefore to investigate the optimized geometry of foam ribs and the influence of the flow path.

Stuwi-Geometrieoptimierung-im Strukturleichtbau© Arburg
Arburg Allrounder for foaming long-fiber reinforced thermoplastics

The work is related to this research project:

The project with the acronym “DigiLaugBeh” deals with the development of a digital design methodology for a leaching tank, taking ecological aspects into account. In addition to the simulative design, the influence of plasticization and tool geometry on the fiber length during foam injection molding, which is to be used to improve the weight-specific properties of long-fiber-reinforced thermoplastics, must also be investigated in more detail.

Project partners:

Bosch, Celanese, PEG, M2M, BSH, Fraunhofer and the University of Stuttgart

These could be your tasks:

Production of samples on the injection molding machine Production of samples on the injection molding machine
Analysis of fiber distribution Analysis of fiber distribution, length and foam morphology
Or: Analysis of foam morphology Or analysis of warpage and dimensional accuracy

These are your benefits:

  • Immediate start possible
  • Work in a competent, young and motivated team
  • Good support and instruction on the systems
  • Direct cooperation with industrial companies
  • Highly relevant industrial topic
  • Industrially established new system technology
  • Co-design of current research projects
  • Individual coordination of tasks and time frame

Your profile:

  • Student of mechanical engineering, materials science, industrial engineering, materials engineering, etc.
  • Enthusiasm for practical work on the machine
  • Communicative and a team player
  • Motivation and commitment