Internship/Working student/Master Thesis student (m/f/d) Simulation, Prototyping and Testing of Next Generation of Agile Actuator Mechanisms

📍 Job Overview

Job Title: Internship/Working Student/Master Thesis Student (m/f/d) Simulation, Prototyping and Testing of Next Generation of Agile Actuator Mechanisms Company: ABB Location: Mannheim, Baden-Württemberg, Germany Job Type: Internship / Working Student / Master Thesis Category: Engineering Operations / R&D Operations Date Posted: August 11, 2025 Experience Level: Entry Level (Intern/Working Student) Remote Status: On-site

🚀 Role Summary

• This role focuses on hands-on experience in the simulation, prototyping, and testing of advanced actuator mechanisms within a leading global technology company, offering a deep dive into R&D operations.
• The position requires building complex simulation models using industry-standard Multibody Dynamics and Finite Element Analysis (FEA) tools, bridging theoretical knowledge with practical application.
• Key responsibilities include the design and execution of physical tests on advanced test rigs, requiring meticulous setup, concept definition, and rigorous evaluation of measurement data.
• This opportunity is ideal for students seeking to refine their skills in applied mechanics, mechatronics, and automation, contributing to the development of next-generation agile actuation systems.

📝 Enhancement Note: While the title mentions "Internship/Working student/Master Thesis student," the core responsibilities and the need for simulation and testing expertise suggest a role that extends beyond typical administrative internships. It's positioned as a substantive R&D contribution. The focus on "next generation" implies involvement in cutting-edge technology development.

📈 Primary Responsibilities

• Develop and validate simulation models for highly complex mechanical and mechatronic systems using industry-leading Multibody Dynamics (MBD) and Finite Element Analysis (FEA) software suites.
• Design, build, and execute physical prototypes and advanced test rigs in a laboratory environment, ensuring accurate data acquisition and adherence to testing protocols.
• Define testing concepts, set up measurement instrumentation, and meticulously analyze and interpret collected data to validate simulation models and assess prototype performance.
• Propose and implement innovative ideas for the optimization of existing hardware solutions and/or simulation processes to enhance design efficiency and product performance.
• Collaborate effectively with cross-functional R&D team members, staying abreast of emerging technological trends and advancements in control systems and protection devices.
• Document all simulation processes, experimental procedures, results, and findings professionally, preparing comprehensive reports and presentations for internal stakeholders.

📝 Enhancement Note: The responsibilities emphasize a blend of theoretical modeling, practical engineering, and analytical skills. The expectation to "apply your own ideas" suggests a degree of autonomy and innovation is encouraged, which is a strong indicator of a valuable R&D operations role.

🎓 Skills & Qualifications

Education:

• Pursuing a Master's degree in Mechanical Engineering, Mechatronics, or a closely related technical field.

Experience:

• Demonstrated experience or strong academic foundation in one or more of the following operational areas: Applied Mechanics, Mechatronics principles, Multibody Dynamics Simulation, Finite Element Analysis (FEA) and Design, or Prototyping and Testing of Mechatronic/Mechanical Systems.

Required Skills:

• Proficiency in at least one of the following simulation and design software packages: ANSYS, Adams, MATLAB/Simulink, or SolidWorks.
• Strong understanding of mechanical system dynamics, mechatronic principles, and control system integration.
• Experience in designing and conducting physical experiments, including test rig setup and data acquisition.
• Excellent analytical and problem-solving skills for interpreting complex simulation and experimental results.
• Proficiency in English, both written and spoken, for effective communication and documentation.
• Ability to work independently and collaboratively within an R&D team environment.

Preferred Skills:

• Hands-on experience with prototyping tools and techniques, including 3D printing or CNC machining.
• Familiarity with scripting languages (e.g., Python) for data analysis or automation.
• Knowledge of sensor integration and data acquisition systems.
• Experience with agile methodologies in a product development context.
• Prior exposure to industrial automation or actuator systems.

📝 Enhancement Note: The requirement for specific software packages (ANSYS, Adams, MATLAB/Simulink, SolidWorks) is a key indicator of the technical depth expected. The emphasis on both simulation and physical testing points towards a well-rounded R&D operations role.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Demonstrate practical application of simulation tools (ANSYS, Adams, MATLAB/Simulink) through academic projects or previous work experience, showcasing model building and analysis capabilities.
• Provide examples of designed or tested mechanical/mechatronic prototypes, highlighting the process from concept to realization and performance evaluation.
• Showcase experience with data acquisition and analysis from physical tests, including the interpretation of measurement results and their correlation with simulation outputs.
• Include documentation of process optimization efforts, whether in simulation workflows or hardware design, demonstrating an understanding of efficiency improvements.

Process Documentation:

• Evidence of creating clear and concise documentation for simulation setups, experimental procedures, and results analysis.
• Examples of workflow design or optimization, particularly in the context of R&D engineering processes.
• Demonstration of how data from testing is used to refine simulation models or improve hardware designs.

📝 Enhancement Note: While not explicitly stated as a "portfolio" requirement, the nature of the role and the associated responsibilities strongly imply that candidates will be expected to showcase their practical skills and project experience. This is a standard expectation for technical internships and thesis projects in an R&D setting.

💵 Compensation & Benefits

Salary Range:

• As this is an internship/working student/master thesis position, compensation will be commensurate with experience and academic level, in line with German industry standards for student roles. Typically, working student positions in engineering fields in Germany can range from €12-€18 per hour, depending on the company, location, and specific responsibilities. For a full-time equivalent internship of 40 hours/week for 6 months, this would translate to approximately €19,200 - €28,800 annually.

Benefits:

• Appropriate remuneration for the duration of the internship/working student period.
• Opportunity to gain extensive practical experience in a leading global technology company.
• Access to state-of-the-art laboratory equipment and R&D facilities.
• Mentorship and guidance from experienced R&D professionals and the R&D Team Lead.
• Exposure to cutting-edge technological trends and innovation in actuator mechanisms.
• Networking opportunities within ABB's international corporate structure.
• Potential for future career engagement within ABB.

Working Hours:

• Full-time (40 hours per week) is implied by the "FULL_TIME" employment type and the typical duration of such roles, though flexibility may be offered for working student arrangements. The internship duration is generally limited to six months.

📝 Enhancement Note: The job posting mentions "appropriate remuneration" and highlights the value of the experience gained. Salary for internships/working student roles in Germany is typically regulated by minimum wage laws and industry practice, with higher rates common for university students in technical fields.

🎯 Team & Company Context

🏢 Company Culture

Industry:

• ABB operates within the Industrial Automation and Electrification sectors, focusing on technologies that drive energy efficiency, sustainability, and digital transformation across various industries, including manufacturing, energy, transportation, and infrastructure. This context means the R&D operations are geared towards practical, high-impact solutions for real-world industrial challenges.

Company Size:

• ABB is a large, multinational corporation with a significant global presence, employing tens of thousands of people worldwide. This scale offers ample resources, diverse projects, and a structured environment for professional development.

Founded:

• ABB was founded in 1988 through the merger of Asea (Sweden) and Brown Boveri (Switzerland). This long history in industrial innovation provides a stable foundation and a deep well of expertise, influencing a culture that values both tradition and forward-thinking technological advancement.

Team Structure:

• The role reports to the R&D Team Lead, indicating a hierarchical R&D structure with clear leadership.
• The student will be part of a specialized R&D team focused on actuator mechanisms, likely comprising engineers with expertise in mechanical design, simulation, electronics, and control systems.
• Collaboration is expected with prototyping teams and other internal R&D engineers, suggesting a matrixed or project-based team interaction model within the broader R&D department.

Methodology:

• The role involves a blend of simulation-driven design (using MBD and FEA) and experimental validation, reflecting a rigorous engineering methodology that integrates theoretical modeling with empirical testing.
• Emphasis is placed on iterative design, optimization, and data-driven decision-making to refine actuator mechanisms.
• The company's focus on "future-focused" and "next generation" technologies implies an agile and innovative approach to R&D processes.

Company Website:

• https://careers.abb/global/en

📝 Enhancement Note: ABB's status as a global leader in industrial technology implies a robust R&D infrastructure and a culture that values innovation, efficiency, and practical application of engineering principles. The company's commitment to sustainability ("leaner and cleaner") likely influences the types of projects undertaken.

📈 Career & Growth Analysis

Operations Career Level:

• This position is firmly at the entry-level or student level, designed for individuals who are still pursuing their higher education but are seeking substantial practical experience. It's an excellent stepping stone into a career in R&D operations, mechanical engineering, or mechatronics.

Reporting Structure:

• The intern/working student will report directly to the R&D Team Lead. This provides a clear reporting line and direct access to mentorship and project guidance.

Operations Impact:

• Contributions in this role directly influence the development of ABB's next-generation agile actuator mechanisms. Success in simulation accuracy, prototype testing, and process optimization can lead to more efficient, reliable, and innovative products, impacting ABB's competitive edge and market position in industrial automation.

Growth Opportunities:

• Skill Development: Deepen expertise in advanced simulation software (ANSYS, Adams, MATLAB/Simulink), experimental testing methodologies, mechatronics design, and data analysis.
• Industry Exposure: Gain firsthand experience in an industrial R&D environment within a global technology leader, understanding industry best practices and emerging trends.
• Networking: Build professional connections within ABB's R&D department and potentially other business units.
• Career Path: Successful completion of the internship or thesis project can lead to opportunities for full-time graduate roles or further specialized projects within ABB's engineering and R&D divisions.

📝 Enhancement Note: The role is framed as a developmental opportunity, offering significant learning and exposure that can shape a candidate's future career trajectory in engineering and R&D operations.

🌐 Work Environment

Office Type:

• The role is on-site in Mannheim, Germany, indicating a traditional office and laboratory work environment. This setting is crucial for hands-on prototyping and testing activities.

Office Location(s):

• Mannheim, Baden-Württemberg, Germany. This region is a significant industrial and technological hub in Germany, providing a dynamic environment for engineering professionals.

Workspace Context:

• The workspace will likely include access to advanced R&D laboratories equipped for mechanical prototyping, testing, and data acquisition.
• Standard office facilities for simulation work, documentation, and team meetings will also be available.
• Collaboration with team members is expected, suggesting an environment that encourages interaction and knowledge sharing within the R&D team.

Work Schedule:

• The position is listed as "FULL_TIME" (40 hours/week), but flexibility for working student arrangements is common, potentially allowing for a balance between study and work. Internships are typically limited to six months.

📝 Enhancement Note: The on-site requirement is driven by the practical, lab-based nature of the work, which is essential for prototyping and testing.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: Review of application documents (CV, cover letter, enrollment certificate, grades) to assess academic background and relevant skills.
• Technical Interview: Likely involves discussions on mechanical engineering principles, simulation techniques, mechatronics, and experience with specific software tools. Candidates may be asked to elaborate on academic projects or relevant prior experience.
• Practical/Case Study: Potential for a small technical task or case study to evaluate problem-solving skills and approach to simulation or testing challenges. This could involve analyzing a simplified mechanical system or discussing a testing methodology.
• Team/Manager Interview: Assessment of cultural fit, communication skills, motivation, and alignment with the R&D team's working style and ABB's values.

Portfolio Review Tips:

• Highlight Relevance: Curate projects that directly relate to mechanical system simulation, mechatronics, prototyping, and testing.
• Showcase Tools: Clearly indicate which software tools (ANSYS, Adams, MATLAB/Simulink, SolidWorks) were used in each project.
• Quantify Impact: Where possible, quantify the results of your work, such as simulation accuracy improvements, test efficiency gains, or design optimizations achieved.
• Process Clarity: Detail your approach to problem-solving, simulation setup, experimental design, and data analysis.
• Presentation Skills: Be prepared to walk through your projects clearly and concisely, explaining technical details and your contributions effectively.

Challenge Preparation:

• Review fundamental concepts in Applied Mechanics, Multibody Dynamics, Finite Element Analysis, and Control Systems.
• Familiarize yourself with the functionalities and typical applications of ANSYS, Adams, and MATLAB/Simulink.
• Practice explaining complex technical concepts and project outcomes in a clear, structured manner.
• Prepare to discuss your understanding of the product development lifecycle, from design and simulation to prototyping and testing.

📝 Enhancement Note: For student roles, the "portfolio" often refers to academic projects, coursework, and any personal engineering projects. Demonstrating a systematic approach to engineering challenges and a grasp of the tools is key.

🛠 Tools & Technology Stack

Primary Tools:

• Simulation Software: ANSYS (for FEA), Adams (for Multibody Dynamics Simulation), MATLAB/Simulink (for system modeling, simulation, and control design).
• CAD Software: SolidWorks (for 3D modeling and design).

Analytics & Reporting:

• Data Analysis Tools: Potentially MATLAB/Simulink for data processing, or other statistical analysis software depending on project needs.
• Visualization Tools: For presenting results, standard office tools or specialized engineering visualization software might be used.

CRM & Automation:

• While not directly involved in CRM, an understanding of how engineering designs feed into product lifecycle management (PLM) systems and automation workflows within manufacturing is beneficial. Integration tools might be used to manage data flow between different engineering software.

📝 Enhancement Note: Proficiency in the specified simulation and CAD software is a critical technical requirement for this role. Understanding how these tools integrate within a broader product development ecosystem is also advantageous.

👥 Team Culture & Values

Operations Values:

• Innovation: A drive to develop "next generation" technologies and apply new ideas to optimize processes and hardware.
• Excellence: A commitment to high-quality simulation, rigorous testing, and professional documentation and presentation of results.
• Collaboration: Working effectively within a team, sharing knowledge, and supporting colleagues in R&D and prototyping.
• Efficiency: Seeking ways to optimize simulation processes and hardware solutions for better performance and faster development cycles.
• Learning: An openness to learning new technologies and contributing to a knowledge-sharing environment.

Collaboration Style:

• The role requires close collaboration with the R&D Team Lead, other engineers, and potentially technicians in the prototyping lab.
• Expect a team environment that values technical discussion, problem-solving, and mutual support.
• Communication will be key, both in sharing technical findings and in coordinating tasks related to simulation, design, and testing.

📝 Enhancement Note: ABB's culture, as implied by its global leadership and focus on future technologies, likely fosters an environment where technical expertise, teamwork, and continuous improvement are highly valued.

⚡ Challenges & Growth Opportunities

Challenges:

• Model Complexity: Building accurate and efficient simulation models for highly complex mechanical systems can be challenging, requiring deep understanding and careful parameterization.
• Integration: Successfully integrating simulation results with physical prototype testing, troubleshooting discrepancies, and optimizing both processes.
• Data Interpretation: Effectively analyzing and interpreting large datasets from advanced test rigs to draw meaningful conclusions.
• Innovation Application: Translating theoretical ideas into practical, implementable optimizations for hardware or simulation workflows.

Learning & Development Opportunities:

• Advanced Simulation Techniques: Mastering MBD and FEA for complex applications.
• Experimental Design: Developing skills in setting up and executing sophisticated engineering tests.
• Mechatronics Integration: Understanding how mechanical systems, electronics, and control software interact.
• Industry Best Practices: Learning how global companies like ABB approach R&D, product development, and process optimization.
• Professional Communication: Enhancing skills in technical documentation and presentation.

📝 Enhancement Note: The challenges presented are typical of advanced R&D roles and offer significant learning opportunities, which are key selling points for student positions.

💡 Interview Preparation

Strategy Questions:

• Simulation Approach: "Describe your process for building a simulation model for a complex mechanical system. What factors do you consider, and how do you validate your model?" (Focus on your systematic approach, tool knowledge, and validation methods.)
• Testing Experience: "Tell me about a time you designed or conducted a physical test. What was the objective, how did you set it up, and what were the key outcomes or challenges?" (Highlight experimental design, data acquisition, and analysis.)
• Problem-Solving: "Imagine a prototype actuator mechanism is not performing as expected based on simulation. What steps would you take to diagnose the issue?" (Demonstrate logical troubleshooting, considering both simulation and physical factors.)
• Optimization Ideas: "How would you approach optimizing an existing simulation process or a mechanical design? Can you give an example from your studies?" (Showcase your ability to think critically about efficiency and improvement.)

Company & Culture Questions:

• "What interests you about ABB and this specific role focusing on actuator mechanisms?" (Connect your skills and career goals to ABB's mission and the role's technical challenges.)
• "How do you approach collaboration within a technical team?" (Emphasize teamwork, communication, and willingness to learn from others.)
• "What are your career aspirations in the field of mechanical engineering or mechatronics?" (Align your goals with potential growth paths within ABB.)

Portfolio Presentation Strategy:

• Structure: Organize your portfolio by project, clearly stating the objective, your role, the tools used, the process followed, key results, and lessons learned.
• Visuals: Use diagrams, simulation screenshots, photos of prototypes, and graphs of test data to illustrate your work effectively.
• Conciseness: Be prepared to present your most relevant projects within a limited timeframe, focusing on the impact and your specific contributions.
• Technical Depth: Be ready to answer detailed questions about your methodologies, the software you used, and the interpretation of your results.

📝 Enhancement Note: Preparation should focus on demonstrating technical aptitude, a structured problem-solving approach, and a genuine interest in ABB's work, aligning with the company's values of innovation and excellence.

📌 Application Steps

To apply for this operations position:

• Submit your application through the ABB careers portal, ensuring all requested documents (cover letter, CV, certificate of enrollment, current transcript of grades, and other supporting documents) are attached.
• Tailor your CV and cover letter: Highlight specific coursework, projects, and skills related to mechanical engineering, mechatronics, simulation (ANSYS, Adams, MATLAB/Simulink), and testing. Quantify achievements where possible.
• Prepare your academic projects: Review your most relevant projects that showcase your simulation, design, prototyping, and testing capabilities. Be ready to discuss them in detail.
• Research ABB: Understand ABB's business areas, technological focus, and commitment to sustainability and innovation. This will help you tailor your application and answer interview questions effectively.
• Practice technical explanations: Rehearse explaining complex engineering concepts and your project experiences clearly and concisely, as you may need to present your work or discuss technical challenges.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.

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