Advanced complex-shaped 3D-printed metallic monoliths for catalytic converters via laser beam powder bed fusion

  • chair:
  • place:

    PhD Thesis

  • institute:


  • starting date:

    As soon as possible

  • Kontaktperson:

    Dittmeyer, Roland

Organizational Unit

Institute for Micro Process Engineering (IMVT)


Job description

The doctoral thesis focuses on a simulation-based optimization of the 3D geometry of metallic monoliths for use as substrates in exhaust gas catalysis. Targets are uniform coating thickness and metal loading everywhere on the substrate as well as an optimized 3D geometry enabling high mass transfer from the gas flow to the wall-coated catalyst layer.

For 3D printing laser beam powder bed fusion (dmg mori SLM 125) as well as binder jetting (digital metal DMP 2500) is available. Coating of the substrates with promising catalyst supports as well as active metals will be done in collaboration with other projects / groups in the Collaborative Research Center TrackAct. The necessary facilities for coating of 3D printed substrates with suitable catalyst supports will be installed at IMVT in the beginning of the project. Introduction of catalytically active metals will be done by other groups in the CRC, predominantly the group of Michael Türk at KIT ITTK which is the main collaboration partner within the CRC. A mathematical model for the coating of 3D printed metallic substrates shall be developed. This model shall be able to describe the thickness distribution over the substrate surface as a function of the 3D geometry and the coating process. The model shall be used for a systematic optimization of the substrate geometry with a view to homogeneous coatings which is a prerequisite for a low catalyst loading. In addition to this aspect, the second target for the optimization is an improved gas to wall mass transfer at low pressure drop which also depends on the 3D geometry of the substrate. A fully digital workflow is desired connecting parametrized CAD models with the coating model and CFD-based reactor simulations in an optimization loop. Modelling and simulation shall be supported and validated by experimental data and characterization results obtained from samples with defined geometry. Thereby, the geometrical complexity of the samples will be increased over time along with the progress of the work.


Starting date

As soon as possible


Personal qualification

  • Diploma or Master in chemical engineering chemistry or a related relevant discipline
  • Background in CFD simulations and chemical reaction engineering
  • Experience with coatings


Contract duration

Limited to 3 years


Application up to



Contact person in line-management

For further information, please contact Prof. Roland Dittmeyer, phone +49 (0)721 608-24413

The PhD work will be carried out at KIT Campus North and will be supervised by Prof. Roland Dittmeyer. The position (75% E13) is planned for three years.