EngD Position: Simulation-Guided Downgauging and Process Optimization of Recycled-Content Aluminum Trays (EcoTray)

Job description

The focus lies on advancing the digital and experimental design of sustainable deep-drawing processes for downgauged, recycled-content aluminum trays.

The Challenge

Precision-formed aluminum trays are indispensable in high-specification packaging for medical, pharmaceutical, and consumer goods. Currently, these are manufactured using thick virgin aluminum and require intensive trial-and-error setup, resulting in excessive waste, frequent tooling maintenance, and high carbon emissions.

The EcoTray project aims to develop a validated, high-resolution finite element simulation framework that integrates experimentally calibrated material models and tribological behavior for recycled aluminum alloys. This initiative will provide predictive capability and design guidelines for the downgauging of aluminum trays from 160?µm to 130?µm while maintaining performance and minimizing failure risks.

By implementing this platform at FIP-AM@UT, the project bridges cutting-edge academic research with direct industrial relevance, supporting AMCOR’s transition toward circular production models aligned with EU Packaging and Packaging Waste Regulation (PPWR) targets.

Your role

• Work primarily at FIP-AM@UT, applying advanced computational and experimental techniques in a high-tech industrial-academic setting.
• Develop constitutive material models tailored to recycled aluminum sheet forming, and implement them within commercial FE software (e.g., ABAQUS).
• Execute tribological experiments under realistic forming conditions and integrate parametric outcomes into the simulation pipeline.
• Validate simulation results through pilot-scale forming trials at AMCOR.
• Deliver a simulation-based decision-support platform that industrial engineers can use to optimize forming processes.
• Publish your findings in peer-reviewed journals and present them at international conferences.
• Collaborate closely with experts at University of Twente, AMCOR, and FIP-AM@UT in a dynamic, interdisciplinary environment.

Your profile

• A Master’s degree in Mechanical Engineering, Materials Science, or a closely related field with strong academic standing.
• Demonstrated expertise in finite element modeling, nonlinear solid mechanics, and computational plasticity.
• Experience with user subroutines (UMAT/VUMAT) in ABAQUS or similar platforms.
• Hands-on experience in mechanical and tribological testing, preferably including strain field measurement techniques such as Digital Image Correlation (DIC).
• Interest in sustainable manufacturing, digital twins, and circular economy solutions.
• Self-driven, structured, and communicative, with excellent English language skills (spoken and written).

Our offer

• A two-year full-time EngD position, jointly hosted at FIP-AM@UT, with academic supervision by the Chair of Nonlinear Solid Mechanics, and industrial guidance from AMCOR.
• Gross monthly salary of  € 3.029,- in accordance with the collective labor agreement for Dutch universities (CAO-NU).
• Attractive secondary benefits, including 8% holiday allowance, 8.3% year-end bonus, generous paid leave (232–328 hours/year), and free campus sports access.
• Enrollment in a customized training curriculum of the Twente Graduate School in computational mechanics, materials processing, and industrial systems design.
• A vibrant, industry-facing research environment at FIP-AM@UT, with access to high-performance computing, precision testing labs, and pilot-scale forming lines.

Information and application

Apply by September 30, 2025, via the “Apply now” button. Your application must include:

• Curriculum Vitae
• Motivation Letter
• Academic transcripts (BSc and MSc)
• Proof of English proficiency (IELTS or TOEFL)
• Contact details of two academic/professional references

For technical inquiries, contact: Dr. habil Celal Soyarslan : +31 5 3489 7499 | [email protected]

Interviews (online or in-person) will be scheduled shortly after the deadline.

Screening is part of the selection process.

About the organisation