Master Thesis Projects - Mechanical Design and Structural Analysis for Vehicle Seats

Thesis Worker at Volvo Cars
Welcome to explore the world of Volvo Cars by writing your thesis with us! As a thesis worker in our organization you are supported by a supervisor who follows you during your project. All thesis projects are arranged in business critical areas and therefore you will be able to contribute to our company purpose – providing freedom to move in a safe, sustainable and personal way – from day one!

About this opportunity - Background
Looking for a master piece for your master thesis project? Innovation starts with being curious. At Volvo Cars, we believe that being curious and truly committed to understanding people is the key to future success. We are people who care about other people, working together to create new technologies and innovations for safe, sustainable and convenient mobility. Want to join us as a Master Thesis student?

We are looking for driven and motivated students interested in pursuing their master thesis within Vehicle Tophat development during the spring term 2025.

Vehicle Tophat is one of six development units within Engineering (R&D) at Volvo Cars where the teams develop state-of-the-art Interior and Exterior. Vehicle Tophat aims to develop the most sustainable and safe Tophat solutions to provide freedom to move in a changing society. Customer value is optimized through attractive designs utilizing new technology trends. Speed to market is important in every aspect of what we do. And we attract and develop talents in a global competitive world, creating an open and transparent environment with a collaborative mindset. Within our team of over 800 engineers at Vehicle Tophat, we are offering a broad range of master thesis projects. 

Seat Platform is a part of the Seat department consisting of approximately 80 engineers organized into five groups, developing components within the following areas: Program & Strategy, Seat Integration, Seat Platform, Seat Tophat, and Function & Control.

At Seat Platform, we are responsible for the development of seat structures, headrest mechanisms, comfort systems and sensors to assure quality of the designs from concept until the end of production phase. We care deeply about the customer, by providing a safe and comfortable environment to make our customers relax and enjoy their time in the car.

At Seat Tophat, we are responsible for the development of seat foams, headrest, armrest, upholstery, harnesses, plastics components, and small metal brackets to assure quality of the designs from concept until the end of production phase. 
You will be involved in developing some of the safest seats in the whole automotive industry.

What you´ll bring
We are looking for candidates with excellent academic records who are open, innovative, driven and team-players. Because of the interdisciplinary nature of our work, we are extending our search to a broad range of competences. If you think that you have what it takes to help us in our journey to deliver safe, human-centric technology, read below on what we do & the various areas we can offer the thesis work in! 
Note: Following are the various thesis projects we have currently on offer within Seat Platform and Seat Tophat development areas. Please specify in your application cover letter, project(s) of your interest.

Project #1: Study to deepen the understanding of cracks
Background: A seat structure needs to withstand high forces and vibrations that could otherwise generate cracks in the metal.
Objective: Better understand how cracks appear and create design guidelines on how to minimize the risk of cracks appearing.
Scope: A focused study and analysis of the lower cross member in the front seat structure to see what type of forces this part is exposed to and try to provoke cracks.

Project #2: Study on vibration signals translated from the vehicle to seat structure 
Background: When a new vehicle platform part is developed it needs to protect the integrity of seat structures in different vehicles. This means a general platform vibration signal is generated at an early stage. As the program develops, more detailed information becomes available on each specific car model and thus the vibration signal becomes more unique.
Objective: Gain deeper understanding of vehicle vibrations translated into seats to be able to define a requirement based on most representative vehicle signal.
Scope: A focused study of the front seat structure to see how different types of vibration signals translate into what type of movement of the front seat. Further it is also relevant to understand how relevant generated vibration signals are to a complete vehicle environment compared to fixed rig tests.

Project #3: Study on vibration signals on how a vehicle tophat can affect complete seat structure performance
Background: When a new vehicle platform part is developed it needs to protect the integrity of seat structures in different vehicles. This means a general platform vibration signal is generated at an early stage. As a program is developed more detailed information becomes available on each specific car model and thus the vibration signal becomes more unique.
Objective: Gain deeper understanding of vehicle vibrations translated into seats to be able to define a requirement based on most representative vehicle signal.
Scope: A focused study of the complete front seat to see how different vehicle tophats can affect the seat structure performance for different types of vibration signals translates into the front seat. 

Project #4: Comfort CAE simulations
Background: CAE is providing a good support tool for the development of components through quick loops of verification through computer simulations of various load cases. Now we want to further develop CAE tools to also support Comfort evaluations which today is subjective and requires a lot of resources to do.
Objective: Develop a method to capture comfort aspects of a seat through pressure mapping simulations and correlate that to different foams and upholstery behavior.
Scope: Take a specific seat and use the material specification to generate a model of a seat with the capability to simulate how different bodies deform the seat and define a comfortable pressure mapping.

Project #5: SPA2 Front and Rear Seat CAE Correlation method development
Background: CAE is providing a good support tool for the development of components through quick loops of verification through computer simulations of various load cases. But to be able to make engineering judgements of simulations we need to trust the results.
Objective: Develop methods to increase the correlation between CAE models and the physical results.
Scope: Take a specific load case and work with comparing physical tests and try to recreate the same behavior in a CAE model.

Project #6: Predict wear & tear on Seat Upholstery with digital tool
Background: In current development we need to rely on our gained knowledge from previous projects and physical testing or even wait for customer complaints when it comes to wear/tear. When developing new concepts/designs on seat upholstery it is time consuming to develop physical samples for testing, and not enough time to wait for customer input. 
If the upholstery could be simulated on the complete seat in a digital environment, with correlating material properties, input can be collected faster and help predict design consequences.
Objective: Find a way to simulate potential wear/tear and design consequences on upholstery on complete seat (modelling in digital environment) including material properties (foam hardness, different surface materials and seams) to avoid late changes which causes cost, time and quality issues. 
Scope: Aim is to identify potential digital tools on the market and propose updates of existing tools. Make samples correlating to tool.

Project #7: Interchangeable/adaptable fixture for Rear Seat
Background: Test rigs are used in different test scenarios, and new rigs are built for each program which is not cost or environmentally effective.
Objective: With an adaptable fixture we can gain time, save cost and re-use material.
Scope: Define prerequisites and design a model for an adaptable fixture and prepare for a prototype. Collaboration with test labs needed.

Project #8: Integration of Headrest into Armrest in Rear seat
Background: Aim is always to understand and fulfill our customer demand, so how to increase the arm comfort and support in low spec cars in rear seat.
Objective: With a longer armrest in the rear seat the comfort and support can be increased.
Scope: Benchmark of competitors, design a concept of an integrated Headrest into Armrest, prepare for prototype and comfort evaluation.

Project #9: Simulation to predict physical H-point in Seat
Background: H-point is a legal requirement that is dependent on many different factors of the seat (comfort requirement, foam density/hardness, upholstery characteristics, dummies etc).
Objective: aim is to find a correlation between simulation and physical parts so in the end we can reduce physical testing to save time and cost.
Scope: Establish simulation method to predict H-Point in Seat - with variables – Upholstery material, Foam density and hardness, comfort components in package. etc. So that physical testing can be reduced.

Duration

Does this sound like your next challenge? Below are some practicalities you need to be aware of: 

• Tentative proposed thesis work period: 20th January 2025 to 27th of June 2025 (dates can be flexible with +/- 7 days)
• Academic credits: equivalent to 30 ECTS 
• Number of students: 1-2 students per project (2 preferred)

Welcome with your application by submitting your resume, cover letter (including which project(s) you would like to work and why) and grades/transcripts via the link below no later than 31st October 2024. We will be continuously reviewing the applications and selecting the candidates, so apply as early as you can!
 

Note that we do not accept any applications via e-mail. If you have any questions regarding the position you are welcome to contact Engineering Manager Seat Platform, Niklas Andersson at niklas.andersson.6@volvocars.com

Volvo Cars - Driving change together
Volvo Cars’ success is the result of a collaborative, diverse, and inclusive working environment. Today, we are one of the most well-known and respected car brands, with around 43,000 employees across the globe. At Volvo Cars, your career is designed around your skills and aspirations, allowing you to reach your fullest potential.