From mechanical engineering studies to the award for young talent in plastics technology

The more insights, the broader the knowledge and experience – that's what Marcel Piechnik, technical project manager at Light Mobility Solutions GmbH, realized during his studies. At the same time, he discovered his enthusiasm for plastics. In many different areas, he has deepened his insights into plastics and their variety.

His commitment is paying off: In June 2024, he won the Young Professionals Award of the SPE Automotive Award 2024 with his master's thesis, as his work has great benefits for practical applications. In the interview, he explains how he discovered his enthusiasm for plastics and which approach has been particularly useful to him so far when starting his career.

First of all, congratulations on winning the Young Professionals Award of the SPE Automotive Award! Can you briefly explain what your master's thesis, which won you the award, was about?

Marcel Piechnik: Thank you very much. My master's thesis deals with the topic "Investigation of injection-molded plastic-metal connections in electric motors". I determined the strengths of plastic-metal hybrid structures that can be achieved in the injection molding process. Specifically, the focus was on the influence of process parameters such as the mold temperature and the temperature of the metal insert, as well as the influence of different pre-treatment methods of the metal surface, such as etching, plasma treatments or the use of adhesion promoters, on the achievable bond strength between an electrical laminate package and glass fiber-reinforced PPS.

What benefits does your work have for practical applications?

Piechnik: The aim is to develop plastic-metal connections in the rotor of an (synchronous reluctance motor) electric motor. The SynR motor is characterized by the fact that no permanent magnets are required, making it independent of the availability and price fluxuations of rare earths. In order to increase the strength of the rotor, particularly at high speeds, the magnetic flux barriers, which were previously filled with air, are to be filled with plastic. The plastic has no negative impact on the electromagnetic properties of the motor. In order to design the optimum rotor geometry, it is necessary to know the achievable connection strength between the electrical steel and the plastic.

What fascinates you most about your area of expertise?

Piechnik: The diversity of the injection moulding process and the range of tasks and challenges involved in optimizing a component: From the plastic-compatible design of the component, the selection of the right material and the possibilities of influencing its properties and behaviour with additives, to the optimization of the production process by determining the optimum process parameters. When developing and manufacturing injection-molded components, there are many parameters and influencing factors that need to be taken into account, making this field an exciting challenge. 

What does your job look like in practice, what tasks do you complete?

Piechnik: As a technical project manager for plastic components in the automotive sector, you are responsible for all technical aspects of component development. This includes concept creation and design, coordination with other specialist areas such as production, toolmaking and assembly. As a career starter, the initial focus is on CAD design and evaluating the technical feasibility of various concept ideas. In the next step, you will be given responsibility for your own projects and will be fully in charge of them.

How did you decide to study plastics?

Piechnik: My interest in materials science was triggered during my bachelor's degree in a mechanical engineering course, which I then deepened with the lecture "Introduction and Fundamentals of Plastics Technology". I also started working as a student assistant at the Institute of Plastics Technology at the University of Stuttgart at the end of my bachelor's degree. During my work, I gained many exciting insights into various areas of plastics technology, such as materials technology, production engineering and plastics testing. I really wanted to deepen and expand these experiences, which is why I decided to choose plastics engineering as a major or specialization in my master's degree.

What advice would you give to people starting out in the industry?

Piechnik: As I'm still a young professional myself, I can perhaps extend this question a little to my time at university. For me, an important point was to gain as much practical experience as possible during my studies. In my case, this was through working as a student assistant, where I got to know everyday working life at the institute, and through an additional internship at Audi AG in Neckarsulm, where I was able to gain exciting insights into the development processes in a large company. Even if you focus on specific areas during your studies, I can still advise you to apply as broadly as possible. There are topics that cannot be taught in lectures but can only be learned in practice. This is a particular challenge as a young professional, but also offers the opportunity to gain a lot of important experience.