Interdisciplinary research programme for sustainable aviation propulsion systems

The aim is to train the next generation of interdisciplinary scientists in the field of aviation research and to make an important contribution to more sustainable aviation technology in the future.

Innovative research for low-emission aviation

Aviation needs new and lightweight propulsion technologies to reduce emissions. Additive manufacturing plays a key role here, as it enables complex and weight-optimised components that are crucial for electric drive systems. This is precisely where the ['skai]-lab cooperation comes in by strategically combining the expertise of additive manufacturing (BAM, BTU) and non-destructive testing (BAM) with the application requirements for innovative drive concepts and components in aviation (DLR, BTU).

The focus is on additively manufactured components for electric drive systems - from electric motors and gearboxes to heat exchangers. The combination of state-of-the-art manufacturing technologies with non-destructive testing methods and data-driven process optimisation results in high-performance, durable and resource-efficient components.

"With ['skai]-lab, we are setting new standards for 3D printing in aviation. Our goal is to jointly develop innovative materials and manufacturing processes that not only meet the highest quality and safety standards, but also contribute to low-emission aviation through more efficient use of resources," explains BAM President Prof. Dr Ulrich Panne.

Doctoral students at the centre

The core of the programme is a unique qualification programme for doctoral students that provides a comprehensive understanding of the entire value chain - from production and quality control to regulatory framework conditions. This is complemented by soft skills courses, summer schools and international research visits. The aim is to train highly qualified experts who will take on a pioneering role in science, industry and the public sector in the future and bring with them precisely the skills that industry needs for technological change.

BTU President Prof. Dr Gesine Grande: "The cooperation in the ['skai]-lab offers our doctoral students the unique opportunity to acquire interdisciplinary skills in manufacturing technologies and quality assurance in order to actively contribute to sustainable aviation of the future."

Networking and international visibility

['skai]-lab is closely integrated into the international research network of DLR, BAM and BTU. As a result, doctoral students benefit from intensive interdisciplinary exchange, comprehensive scientific expertise and access to state-of-the-art research infrastructure. Co-operations with leading companies such as Airbus and MTU as well as support from national professional associations and an external advisory board build a bridge to industrial practice.

"The close cooperation between the research institutions with a focus on future industrial needs in the ['skai]-lab creates a unique environment for advancing the use of electric drive technologies for aviation and thus significantly reducing CO₂ emissions," emphasises Prof. Dr Lars Enghardt, Director of the DLR Institute of Electrified Aero Engines and Head of the BTU chair of the same name.

Research projects with real added value

The programme will initially start with nine doctoral projects, three at each participating research institution. They cover the entire process chain: from the development of additively manufactured heat exchangers and waveguide windings for e-machines to data-driven optimisation using Physics-Informed Neural Networks (PINN) and robust methods of Structural Health Monitoring (SHM). Particular attention is paid to sustainability, resource efficiency and reducing CO₂ emissions.

The first doctoral studies are to be completed by 2030. In this way, ['skai]-lab is creating an excellent basis for new scientific findings, the further development of innovative technologies and the sustainable transfer of knowledge. At the same time, the programme contributes to the training of highly qualified scientists.