Composite Structural Engineer

ACT Blade Europe S.r.l. is an innovative SME focused on the design, development and industrialisation of high-efficiency wind turbine blades. The ACT Blade technology, protected by two international patent families, introduces a novel blade architecture combining an internal composite structure with a highly engineered textile shell forming the blade's aerodynamic surface. The technology is designed to significantly reduce the cost of wind energy by enabling lighter, longer and more efficient blades.

ACT Blade Europe is currently progressing through product development, proof-of-concept and industrialisation, including full-scale validation, development of scalable manufacturing processes. and achievement of the product certifications required under international IEC 61400 standards for commercial deployment. Its first commercial product, the ACT100, is a 49.2-metre blade designed for the Senvion MM92 2 MW wind turbine platform and targeted at the retrofit and life-extension market, with the objective of increasing annual energy production while extending the operating life of existing assets.

ACT Blade Europe S.r.l. is seeking a Composite Structural Engineering Intern with strong competencies in Finite Element Method (FEM) / Finite Element Analysis (FEA) and, preferably, experience with Abaqus or comparable advanced structural simulation software.

The internship will support the ongoing development, validation and industrialisation of ACT100, ACT Blade's first full-scale wind turbine blade product. ACT100 is based on ACT Blade's patented architecture, which combines an internal composite load-bearing structure with a highly engineered textile shell. This unconventional configuration requires advanced structural modelling and validation to ensure that the blade meets demanding performance, durability and certification requirements.

The intern will work closely with ACT Blade's engineering team on the development and refinement of numerical models used to assess structural behaviour under relevant loading conditions. Activities are expected to include the modelling of composite components, analysis of stresses, strains, deformations, buckling and failure modes, sensitivity studies, and comparison of numerical predictions with available test and design data.

The candidate's expertise will be particularly important in supporting the transition from prototype and proof-of-concept activities towards a robust, certifiable and industrially scalable product. The role therefore directly contributes to the wider innovation project objectives of validating the ACT100 design, reducing technical risk, improving structural efficiency, and preparing the product for industrialisation and market deployment.

Key Outcomes

The internship will provide the candidate with hands-on experience in the structural development of a highly innovative, full-scale wind energy product and exposure to the engineering challenges associated with advanced composite structures, product certification and industrialisation.

The internship will aim to develop and strengthen competencies in:

• Advanced FEM/FEA modelling of composite structures, preferably using Abaqus.
• Definition and implementation of composite material properties, lay-ups, boundary conditions and load cases.
• Structural assessment of wind turbine blade components under static and fatigue-related loading conditions.
• Evaluation of stresses, strains, deflections, buckling behaviour and potential failure mechanisms.
• Mesh development, model convergence and sensitivity studies.
• Interpretation and validation of simulation results against analytical calculations, test data and engineering requirements.
• Identification of design optimisation opportunities aimed at improving structural performance, reducing weight and supporting manufacturability.
• Preparation of clear technical documentation, simulation reports and engineering evidence supporting design reviews and certification activities.
• Collaboration with a multidisciplinary engineering team working across structural design, materials, manufacturing and product validation.

Expected outputs may include updated and validated finite element models, structural assessment reports, sensitivity and optimisation studies, and engineering recommendations supporting the next stages of ACT100 product development and industrialisation.

These activities will directly contribute to the innovation project by improving confidence in the structural performance of ACT100, supporting design verification and certification, and helping establish a reliable engineering basis for scalable production and future product variants.

Type of Stream

Deep-Tech Talents (research-focused internship)

The internship is strongly aligned with the Deep-Tech Talents stream, as it involves advanced engineering analysis, applied research and the use of sophisticated numerical modelling tools to support the development and validation of an innovative wind energy technology.

Required Qualifications

1. Degree Level

Candidates should be currently enrolled in, or have recently completed, a Master's degree or equivalent advanced degree in one of the following or a closely related field:

• Mechanical Engineering
• Aerospace Engineering
• Structural Engineering
• Composite Materials Engineering
• Materials Engineering

Strong candidates at an advanced stage of a Bachelor's degree with substantial relevant FEM/FEA and composite-structures experience may also be considered.

2. Specific Technical Skills

The candidate should demonstrate:

• Good knowledge of Finite Element Method (FEM) and structural analysis principles.
• Practical experience with FEA software, preferably Abaqus.
• Understanding of the mechanical behaviour of composite materials and laminated structures.
• Ability to define material properties, constraints, loads and boundary conditions in numerical models.
• Understanding of stress, strain, stiffness, deformation and structural stability analysis.
• Familiarity with mesh generation, convergence assessment and numerical result interpretation.
• Ability to analyse and present engineering results in a structured and technically rigorous manner.
• Good general understanding of structural mechanics and failure mechanisms.

Soft Skills

The role requires a candidate who can operate effectively within a small, technically intensive and multidisciplinary deep-tech environment. Important interpersonal and organisational skills include:

• Strong analytical and problem-solving capability.
• Attention to detail and a rigorous engineering approach.
• Ability to work independently while seeking guidance when appropriate.
• Ability to collaborate effectively with engineers from different technical disciplines.
• Good written and verbal communication skills, particularly the ability to explain numerical results and engineering conclusions clearly.
• Curiosity and willingness to investigate non-conventional engineering solutions.
• Ability to organise work, manage priorities and document technical activities systematically.
• Proactive attitude and willingness to contribute to an evolving product-development environment.

Preferred Qualifications

The following would be advantageous but are not essential:

• Previous experience with Abaqus/CAE and, where relevant, scripting or automation within Abaqus.
• Experience modelling composite laminates, sandwich structures or large composite components.
• Knowledge of composite failure criteria and progressive damage modelling.
• Experience with buckling, nonlinear analysis, contact modelling or fatigue-related structural assessment.
• Familiarity with Python, MATLAB or similar engineering analysis tools.
• Previous experience in the wind energy, aerospace, marine or advanced composites sectors.
• Knowledge of wind turbine blade structures and load cases.
• Awareness of product certification and engineering standards, particularly IEC 61400 or comparable structural certification frameworks.
• Experience comparing numerical simulations with experimental or full-scale structural test data.