ELI - Stage Technology Lab & Inspection

Leonardo; Varese; Hybrid; EUR 8,900 - 12,000; Full time

Benefits offered by this job

Hybrid working arrangement

Monthly stipend €800

Job summary

Leonardo seeks a Master’s thesis intern for the Technology Lab & Inspection team in Cascina Costa (VA). You will develop and validate LPBF models, predicting temperature, residual stresses, and distortions, supporting AM advancement for aerospace.

The role blends research and industrial application within a multidisciplinary environment. The project focuses on digital engineering for AM, with deliverables including model development, validation against data, and a thesis documenting

Qualifications

• Solid analytical and problem-solving capabilities.
• Fundamental knowledge of heat transfer, solid mechanics, and numerical methods.
• Basic understanding of Finite Element Analysis (FEA).
• Strong interest in AM and Materials Engineering.
• Ability to work effectively in a team and in a structured engineering environment.

Responsibilities

• Review the state-of-the-art in AM process simulation.
• Definition and implementation of finite element or numerical models for LPBF processes.
• Application of appropriate material models and boundary conditions.
• Execution of simulation campaigns.
• Analysis and interpretation of outputs (thermal fields, stress distribution, distortion).
• Correlation with experimental evidence where available.
• Contribution to internal best practices and methodological guidelines.

Skills

Analytical thinking

Heat transfer

Solid mechanics

Numerical methods

Familiar with teamwork

English proficiency

Education

Ongoing Master’s Degree in Mechanical, Materials or Aeronautical Engineering

Background in Materials Science, Manufacturing Processes, or Structural/Mechanical Analysis

Tools

Abaqus

Ansys

Simufact Additive

Python

MATLAB

Job description

Job Description

Leonardo is an international industrial group and one of the world's leading companies in the Aerospace, Defence, and Security sectors, delivering multi-domain technological capabilities in the fields of Helicopters, Aircraft, Aerostructures, Electronics, Cyber Security, and Space. With more than 60,000 employees worldwide, the company has a strong industrial presence in Italy, the United Kingdom, Poland, and the United States, and operates in 150 countries through subsidiaries, joint ventures, and equity investments. A key player in major strategic programs at the global level, Leonardo is a technology and industrial partner to governments, defence administrations, institutions, and businesses.

Within the Engineering area, we are seeking a Stage Technology Lab & Inspection in Cascina Costa (VA).

Job Description Summary

Within the Engineering Directorate, the Technology Lab & Inspection function is responsible for the development and qualification of materials and processes, as well as for the industrial support across the product lifecycle.

The proposed internship is specifically addressed to Master’s Degree in Aerospace/Mechanical/Materials Engineering students and it is intended to be carried out as part of a final thesis project (Master’s thesis).

As a Master’s thesis intern within the Technology Lab & Inspection – Metallic Materials Science & Testing team, the candidate will support the development of numerical simulation methodologies for Metal Additive Manufacturing processes, contributing to both research and industrialization efforts.

The activity is part of ongoing initiatives aimed at strengthening the company’s capabilities in Additive Manufacturing (AM) for aerospace applications.

Role Overview

The selected candidate will contribute to a research project focused on the simulation of Laser Powder Bed Fusion (LPBF) processes, with the objective of enhancing predictive capabilities related to process-induced thermal and mechanical phenomena.

The candidate will operate in a multidisciplinary environment, contributing to the advancement of digital engineering approaches applied to AM technologies.

Objectives

The primary objective of the internship is to develop and validate numerical models of LPBF processes, enabling the prediction of key physical phenomena such as temperature evolution, residual stresses, and part distortions.

Expected deliverables include:

• Development of simulation models (thermal and/or thermo-mechanical).
• Validation against available experimental or reference data.
• Sensitivity analyses of relevant process parameters.
• Preparation of a structured Master’s thesis report documenting activities, methodologies, and results.
• Formulation of recommendations to support industrial application and future developments.

Key Activities

The candidate will be involved in the following activities:

• Review of the state-of-the-art in AM process simulation.
• Definition and implementation of finite element or numerical models for LPBF processes.
• Application of appropriate material models and boundary conditions.
• Execution of simulation campaigns.
• Analysis and interpretation of outputs (e.g. thermal fields, stress distribution, distortion).
• Correlation with experimental evidence, where available.
• Contribution to internal best practices and methodological guidelines.

Candidate Profile

Required Skills and Competencies

• Solid analytical and problem-solving capabilities
• Fundamental knowledge of heat transfer, solid mechanics, and numerical methods
• Basic understanding of Finite Element Analysis (FEA)
• Strong interest in AM and Materials Engineering
• Ability to work effectively in a team and in a structured engineering environment

Preferred Qualifications (Nice to Have)

• Familiarity with simulation tools (e.g. Abaqus, Ansys, Simufact Additive, or equivalent)
• Basic programming skills (e.g. Python, MATLAB)
• Knowledge of metallurgical aspects related to AM
• Previous academic experience in AM or process simulation

Education and Requirements

• Ongoing Master’s Degree in Mechanical, Materials or Aeronautical Engineering
• Availability to carry out the internship as a Master’s thesis project (Tesi Magistrale)
• Academic background in Materials Science, Manufacturing Processes, or Structural/Mechanical Analysis
• Good command of English (written and spoken)

WHAT WE OFFER

Engagement, recognition of skills, and a strong focus on people's well-being and safety are the cornerstones of our corporate culture.

Every day, we are committed to fostering an inclusive and stimulating work environment by actively promoting the principles of inclusion, equity, and diversity enhancement.

Our reference collective labor agreement is the National Collective Labor Agreement (CCNL) for the Private Metalworking Industry and Plant Installation Sector.

Working arrangement: Hybrid

Employment category: Curricular Internship

Contract type: Internship

Gross monthly expense reimbursement: €800,00

Ongoing training and professional development opportunities, including both technical and soft skills

Well-being: We place the economic, physical, social, and psychological well-being of our people first, offering a variety of solutions tailored to their needs.

The company reserves the right to assess the appropriate employment level and compensation package based on objective criteria emerging during the selection process and in line with the seniority of the selected candidate and the position itself, in accordance with the principles of fairness, transparency, and equal opportunities established by applicable legislation.

Primary Location

IT - Varese - Cascina Costa