From Complex Problems to Powerful Solutions –
Engineering Success Stories That Drive Results
Every project tells a story —
of complex challenges, methodical analysis, and sustainable, results-driven solutions.
Here, I present selected engineering projects that showcase my scientific expertise, innovative thinking, and measurable outcomes.
Discover how technical excellence and engineering know-how turn challenges into tangible success.
Process Validation and Optimization of Ultrasonic Metal Welding (USMW) for Cell Contacting Systems (CCS)
Methodical analysis and experimental validation of the serial production process using the Design of Experiments (DoE) approach
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Result:
Enhanced process stability and reduced scrap rate through optimized process parameters and targeted process monitoring – with a specific focus on detecting latent defects that are not identifiable via conventional process metrics
High-Temperature Turbomachinery Components Made from Gamma Titanium Aluminide
Comprehensive feasibility analysis of investment casting, centrifugal casting, and forging processes — with a specific focus on alloy-dependent process compatibility
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Result:
Step 1: Successful design and validation of prototype components
Step 2: Successful validation up to pre-series production and establishment of an alternative manufacturing route in Europe
Demonstration of high-temperature suitability (up to 1000 °C) according to application-specific material specifications
Electrochemical Machining (ECM) of Gamma-TiAl Turbomachinery Components
Development and validation of an ECM process for the precision manufacturing of highly complex component geometries
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Result:
Successful feasibility study and demonstration of ECM machining on geometrically demanding prototypes
Advanced Manufacturing Process Development for Turbomachinery Applications
Technological feasibility studies of EBM, MIM, and CIM manufacturing processes with respect to material properties, process capability, and economic viability
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Result:
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Proof of concept and performance validation of AM-based components
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Potential analysis for series production suitability
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Establishment of a robust supply chain for additive manufacturing processes
Process Optimization: Precision Turning of a Turbomachinery Component
In-depth process analysis of the turning operation, including target vs. actual cycle time comparison and identification and implementation of optimization potentials
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Result:
10% scrap reduction in series production combined with shorter cycle times through targeted process optimizations