Postdoc in CFD Modelling of Continuous-Fiber 3D Printing - DTU Construct

DTU - Technical University of Denmark; Kongens Lyngby; On-site; DKK 389,000 - 478,000; Full time

Job summary

DTU – Technical University of Denmark is seeking a Postdoctoral Researcher to advance high‑fidelity CFD modelling of extrusion‑based 3D printing with continuous fibers. You will develop a CFD model in OpenFOAM, couple matrix flow with fiber mechanics, and connect processing parameters to fiber architecture and part quality.

The role involves translating parameters into predictive models and exploring reduced‑order approaches to speed up simulations for potential integration into slicer and

Qualifications

• PhD in a relevant field required.
• Strong background in CFD, numerical modelling and multiphysics simulations.
• Experience with polymer processing or additive manufacturing is advantageous.
• Ability to develop, extend or couple solvers for high-fidelity simulations.

Responsibilities

• Develop a high‑fidelity CFD model of material extrusion for continuous‑fiber thermoplastics using OpenFOAM.
• Couple matrix flow with fiber‑scale mechanics (e.g., via CalculiX) to capture fiber tension and interfacial behavior.
• Translate process parameters into predictive models linking fiber architecture, rheology and part quality.
• Explore reduced‑order modelling to accelerate simulations for slicer/toolpath planning integration.

Skills

CFD

OpenFOAM

CalculiX

FEM

Multiphysics

Numerical modelling

Education

PhD degree

Tools

OpenFOAM

CalculiX

Job description

Job Description

Are you excited about advancing high-fidelity numerical modelling for continuous-fiber additive manufacturing?

Are you excited about advancing high-fidelity numerical modelling for continuous-fiber additive manufacturing?

We are seeking a highly motivated Postdoctoral Researcher to develop a Computational Fluid Dynamics (CFD) model capturing the behaviour of thermoplastic matrix and continuous fibers during extrusion-based 3D printing. In this role, you will combine process modelling with fiber-matrix interaction analysis to link process parameters to fiber architecture and interfacial quality. Working within the EU-funded ASPIRE project on large-scale additive manufacturing of lightweight EV battery packs, you will help enable digitally guided optimisation of continuous-fiber 3D printing. Our research focuses on developing and applying digital technologies such as additive manufacturing/3D printing, numerical modelling, artificial intelligence, automation and robotics, digital twins, and smart materials.

Responsibilities And Qualifications

Your work will focus on developing a high-fidelity Computational Fluid Dynamics (CFD) model of material extrusion for continuous-fiber reinforced thermoplastics, implemented primarily in OpenFOAM. You will couple the matrix flow with fiber-scale mechanics, for example via an FEM solver such as CalculiX, to capture fiber tension, alignment, and interfacial behavior during printing. Working closely with the experimental team, you will translate process parameters into predictive models linking fiber architecture, matrix rheology, and printed part quality, and explore reduced‑order modelling approaches to accelerate simulations for potential integration into slicer and toolpath‑planning software.

We envision that:

• You have an open and creative mindset and can think across disciplines, combining computational fluid dynamics, materials science, and digital fabrication.
• You have a solid background in computational fluid dynamics, numerical modelling, or multiphase/coupled flow simulation, ideally applied to polymer processing or additive manufacturing.
• You are eager to explore the newest developments in 3D printing and test innovative modelling approaches to advance the field.
• You have strong hands‑on experience with OpenFOAM and are comfortable developing, extending, or coupling custom solvers.
• You have experience with coupled or multiphysics simulation, e.g. linking CFD with a structural/FEM solver (such as CalculiX) to resolve fiber behavior within a flow field.

Furthermore, it is an additional advantage if you have:

• Knowledge of fiber‑reinforced polymers and their rheological, mechanical, or thermal behavior.
• Experience with rheological constitutive modelling (shear‑thinning, temperature‑dependent, or viscoelastic).
• Experience with reduced‑order modelling techniques to accelerate simulation for near‑real‑time or slicer‑integrated use.
• Familiarity with overset/moving‑mesh methods or coupled‑motion CFD approaches (e.g. fluid–structure interaction).

As a formal qualification, you must hold a PhD degree (or equivalent).

We offer

DTU is a leading technical university globally recognized for the excellence of its research, education, innovation and scientific advice. We offer a rewarding and challenging job in an international environment. We strive for academic excellence in an environment characterized by collegial respect and academic freedom tempered by responsibility.

Salary and terms of employment

The appointment will be based on the collective agreement with the Danish Confederation of Professional Associations. In addition, supplements can be negotiated in accordance with DTU’s salary structure for scientific staff: www.inside.dtu.dk/en/human-resources/during-employment/salary/salary-structures .

The period of employment is 2 years and 8 months. Starting date is 1 November 2026 (or according to mutual agreement). The position is a full‑time position.

You can read more about career paths at DTU here .

Further information

Further information may be obtained from Professor Jon Spangenberg ( [e-mail] ) and Assistant Professor Berin Seta ([e-mail] ).

You can read more about Department of Civil and Mechanical Engineering at www.https://construct.dtu.dk/ .

If you are applying from abroad, you may find useful information on working in Denmark and at DTU at DTU – Moving to Denmark .

All interested candidates irrespective of age, gender, disability, race, religion or ethnic background are encouraged to apply. As DTU works with research in critical technology, which is subject to special rules for security and export control, open‑source background checks may be conducted on qualified candidates for the position.

DTU Civil and Mechanical Engineering develops and utilizes science and technical knowledge for the benefit of society and sustainable development. We undertake research, education, innovation, and scientific advice of the highest quality within building design and processes, building construction and safety, building energy and services, solid mechanics, fluid mechanics, materials technology, manufacturing engineering, engineering design and thermal energy systems.

DTU – For the benefit of society since 1829

DTU is one of Europe’s leading elite technical universities. Through research and education at an international top level, we create solutions to the major societal challenges of our time and help secure Europe’s global leadership in sustainable technological development. Since Hans Christian Ørsted founded DTU almost 200 years ago, our mission has remained the same: We develop and create value through the natural and technical sciences for the benefit of society. DTU has 13,800 students, 1,600 PhD students, and 6,500 employees. We work in an international environment and have an inclusive, stimulating, and informal work culture. DTU has campuses in all parts of Denmark and in Greenland and collaborates with the best universities around the world.