Master's Thesis: Exploring Direct Screw Fastening of Plastic Panels to Vehicle Chassis

About this opportunity - Background

At Vehicle Engineering, our responsibility spans the entire chassis, interior, climate, body & exterior functions, mechanical Integration, and a range of vehicle attributes with impact on design and customer experience of our complete product. Across these domains and all development cycles, we will lead an effective delivery operation on a complete level in close sync with other Engineering units, functions, and stakeholders across the company.

This thesis work is within the area of Team Compartment Trim at Interior Trim & Materials.

Interior vehicle panels, often made from polypropylene (PP) or PC-ABS, serve both functional and aesthetic purposes. Traditionally, these panels are mounted using clips, screws, or hybrid fastening methods. However, with increasing demands for cost efficiency, environmental sustainability, and weight reduction, there is a growing interest in simplifying the design by fastening plastic panels directly to the chassis using screws.

This raises several questions:
•    How much torque can be applied without damaging the plastic?
•    How does plastic behave over time under stress, temperature, and humidity?
•    What is the optimal design of the screw interface in the plastic?

Objective:
The aim of this thesis is to explore the feasibility of direct screw fastening between plastic panels and the vehicle chassis. The focus will be on:
•    Defining force transmission through the joint (screw → plastic → chassis → nut)
•    Determining suitable torque levels for different plastic types
•    Designing an optimal screw interface in the plastic
•    Evaluating long-term performance under environmental stress

Scope of the thesis work

The thesis will include:
•    Material analysis of common plastics (PP, PC-ABS) and their mechanical properties
•    Simulation and/or virtual testing of screw joints between plastic panels and the chassis
•    Identification of relevant load cases and force distribution
•    Virtual evaluation of long-term durability and environmental impact
•    Recommendations for design and fastening strategy

What you'll bring

We’re looking for a student with knowledge in plastics and plastic design, ideally studying mechanical engineering, materials science, or product development. You should be comfortable working theoretically, including CAE and 3D modeling to evaluate designs etc. Collaboration will be key – you’ll work with e.g. engineering teams, materials labs, CAE departments, and plastic suppliers throughout the project.

Duration

•    Tentative proposed thesis work period: 19th January 2026 to 26th of June 2026 (dates can be flexible with +/- 7 days)
•    Academic credits: equivalent to 30 ECTS 
•    Number of students: 2 students per project