Bachelor's or Master's thesis - Prototype Development of Detachable Cell Contacts for Pouch Cells

Location: Darmstadt, DE, 64289

City:

Darmstadt

Date:

Sep 16, 2026

Bachelor's or Master's thesis - Prototype Development of Detachable Cell Contacts for Pouch Cells

Bachelor's or Master's thesis - Prototype Development of Detachable Cell Contacts for Pouch Cells (all genders) Darmstadt

As electric mobility continues to expand globally, the repairability and recyclability of traction batteries are becoming increasingly critical. Current battery modules commonly use welded cell connections, which provide good electrical performance but make maintenance, repair, and recycling difficult: if a single cell becomes defective, the entire module often has to be replaced. At Fraunhofer LBF, we are therefore developing detachable and reusable cell contacting solutions that allow defective cells to be exchanged individually and simplify module disassembly at the end of life.

The thesis focuses on the prototype development and experimental validation of an easily detachable cell contacting solution for pouch-cell battery modules. Based on the detachable cell contact concept selected in a previous thesis, a prototype module will be manufactured by additive manufacturing and conventional machining, assembled with the provided cells, and evaluated on the eMAST test bench under vibration and climate conditions as well as in a driving cycle including charging and discharging.

The cells, additional components, and the complete test infrastructure are provided in-house. The test results will be analysed with regard to mechanical stability, contact reliability, and functional performance, and will contribute to more maintainable, reusable, and recyclable battery systems.

Be part of change

Manufacture a prototype using additive manufacturing and conventional machining methods based on the selected detachable cell contact design from the previous thesis

Integrate the provided cells and additional required components into the module prototype

Prepare and carry out tests on the eMAST vibration test bench in a climate chamber

Perform vibration testing under relevant environmental conditions

Conduct a driving cycle test including charging and discharging of the prototype

Analyse the test results and assess mechanical stability, contact reliability, and functional performance

Document the prototype development, test setup, results, and conclusions

What you contribute

Studies in Mechanical Engineering / Electrical Engineering / Mechatronics or related fields

Interest in battery systems, experimental testing, and prototype development

Basic knowledge of CAD

Experience with testing or battery technology is an advantage

Good command of English and German

What we offer

Hands-on work on site in our battery and vibration test laboratories at Fraunhofer LBF in Darmstadt

An individually tailored task with plenty of creative freedom

A highly topical and practically relevant research topic with direct relevance to the circular economy

The opportunity to actively participate in an innovative and interdisciplinary project

Insight into current developments in battery module design, detachable contacting, and vibration and climate testing

As part of your thesis, we offer exciting professional guidance and valuable practical insights. Please note that the thesis is unpaid.

We value and promote the diversity of our employees' skills and therefore welcome all applications – regardless of age, gender, nationality, ethnic and social origin, religion, ideology, disability, sexual orientation and identity. Severely disabled persons are given preference in the event of equal suitability. Our tasks are diverse and adaptable – for applicants with disabilities, we work together to find solutions that best promote their abilities.

With its focus on developing key technologies that are vital for the future and enabling the commercial utilization of this work by business and industry, Fraunhofer plays a central role in the innovation process. As a pioneer and catalyst for groundbreaking developments and scientific excellence, Fraunhofer helps shape society now and in the future.

Ready for a change? Then apply now and make a difference! Once we have received your online application, you will receive an automatic confirmation of receipt. We will then get back to you as soon as possible and let you know what happens next.

Do you have questions about the job? Our colleague Savan Dihora is here to help: Phone +49 6151 705-573.

Fraunhofer Institute for Structural Durability and System Reliability LBF

www.lbf.fraunhofer.de

Requisition Number: 85679                Application Deadline: