Job Description

Within the Engineering Directorate, the Technology Lab & Inspection function is responsible for the development and qualification of materials and processes, as well as for the industrial support across the product lifecycle.

The proposed internship is specifically addressed to Master’s Degree in Aerospace/Mechanical/Materials Engineering students and it is intended to be carried out as part of a final thesis project (Master’s thesis).

As a Master’s thesis intern within the Technology Lab & Inspection – Metallic Materials Science & Testing team, the candidate will support the development of numerical simulation methodologies for Metal Additive Manufacturing processes, contributing to both research and industrialization efforts.

The activity is part of ongoing initiatives aimed at strengthening the company’s capabilities in Additive Manufacturing (AM) for aerospace applications.

The selected candidate will contribute to a research project focused on the simulation of Laser Powder Bed Fusion (LPBF) processes, with the objective of enhancing predictive capabilities related to process-induced thermal and mechanical phenomena.

The candidate will operate in a multidisciplinary environment, contributing to the advancement of digital engineering approaches applied to AM technologies.

Objectives:

The primary objective of the internship is to develop and validate numerical models of LPBF processes, enabling the prediction of key physical phenomena such as temperature evolution, residual stresses, and part distortions.

Expected deliverables include:

• Development of simulation models (thermal and/or thermo-mechanical).
• Validation against available experimental or reference data.
• Sensitivity analyses of relevant process parameters.
• Preparation of a structured Master’s thesis report documenting activities, methodologies, and results.
• Formulation of recommendations to support industrial application and future developments.

Key Activities:

The candidate will be involved in the following activities:

• Review of the state-of-the-art in AM process simulation.
• Definition and implementation of finite element or numerical models for LPBF processes.
• Application of appropriate material models and boundary conditions.
• Execution of simulation campaigns.
• Analysis and interpretation of outputs (e.g. thermal fields, stress distribution, distortion).
• Correlation with experimental evidence, where available.
• Contribution to internal best practices and methodological guidelines.

Candidate Profile:

Required Skills and Competencies:

• Solid analytical and problem-solving capabilities
• Fundamental knowledge of heat transfer, solid mechanics, and numerical methods
• Basic understanding of Finite Element Analysis (FEA)
• Strong interest in AM and Materials Engineering
• Ability to work effectively in a team and in a structured engineering environment

Preferred Qualifications (Nice to Have)

• Familiarity with simulation tools (e.g. Abaqus, Ansys, Simufact Additive, or equivalent)
• Basic programming skills (e.g. Python, MATLAB)
• Knowledge of metallurgical aspects related to AM
• Previous academic experience in AM or process simulation

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Education and Requirements:

• Ongoing Master’s Degree in Mechanical, Materials or Aeronautical Engineering
• Availability to carry out the internship as a Master’s thesis project (Tesi Magistrale)
• Academic background in Materials Science, Manufacturing Processes, or Structural/Mechanical Analysis
• Good command of English (written and spoken)

Seniority:

Primary Location:

IT - Varese - Cascina Costa

Additional Locations:

Contract Type:

Hybrid Working: