Master Thesis: AI-Driven Simulation of Non-Newtonian Polymer Flow in Cable Extrusion

Background

As offshore wind energy continues to grow, high-voltage (HV) cables are essential for transmitting power from sea to shore. The insulation quality of these cables is largely determined during the extrusion process, where molten polymer layers are applied. Traditional CFD methods can be computationally expensive and time-consuming, especially for non-Newtonian polymer flows.

This thesis aims to accelerate simulation and improve predictive capabilities by integrating Physics-Informed Neural Networks (PINNs) and other AI techniques to model polymer flow dynamics in cable extrusion.

Thesis Objectives

• Explore how neural networks can complement or accelerate traditional CFD simulations in polymer extrusion.
• Develop a PINN-based model to simulate non-Newtonian polymer flow within the extrusion cross-head.
• Compare AI-driven results with conventional CFD outputs and experimental data.
• Investigate the use of PyTorch for training and deployment.

Main Activities

• Conduct a comprehensive literature review on AI-enhanced CFD and PINN applications in fluid mechanics.
• Analyze existing CFD simulations and experimental results to extract insights and guide model development.
• Design, develop, and train neural network models using Python and PyTorch.
• Validate and compare AI-driven models against traditional CFD tools (e.g., Ansys Fluent, Polyflow) and experimental data.
• Prepare clear documentation and deliver engaging presentations of findings.

Qualifications

We welcome applicants from diverse academic and personal backgrounds. If you are passionate about innovation and sustainability, we encourage you to apply—even if you don't meet every requirement.

• Currently enrolled in a Master's program in Mechanical Engineering, Computational Mechanics, Applied Physics, or a related field.
• Experience with Python and PyTorch.
• Solid understanding of fluid mechanics, heat transfer, and numerical simulation.
• Familiarity with non-Newtonian flow modeling is helpful but not required—we'll support you in learning it.
• Strong communication skills in English.

What We Offer

• An inclusive and collaborative environment where your ideas matter.
• Opportunities to contribute to sustainable energy solutions.
• Support from experienced mentors and access to industry-leading tools.
• Flexibility to accommodate different working styles and needs.

At NKT we believe in empowering our team members to thrive both personally and professionally. Our commitment to work-life balance extends beyond mere words; it's woven into the fabric of our company culture. Whether you're working partly from home or collaborating in our vibrant office spaces, we prioritize flexibility, well-being, and harmony. Because when our team members flourish, so does our innovation and growth.

NKT is committed to developing a diverse organization and culture where people of diverse backgrounds can grow and are inspired to do their best. We have high ambitions on establishing gender diversity at NKT and encouraging all interested candidates to apply – even if you don't tick all the boxes described. We believe that a diverse organization enables long-term performance and that an inclusive and welcoming culture creates a better work environment.

If you have any questions regarding the position, you are very welcome to contact Recruiting Manager, Giampaolo Martufi, In case you have any inquiries about the recruitment process please reach out to HRBP Jenny McWhinney, Please note that due to the GDPR regulations we cannot accept any applications via e-mail.

Be a Connector of the green tomorrow

About NKT

Join a diverse and international team of experts developing the power cable technology of the future with focus on deeper sea, lower losses and higher performance. Technology is leading the corporate R&D program including material development and operating some of the most advanced high-voltage test centers in the industry. NKT also operates a Technology Consulting center in Sweden, where technical experts and scientists supports industries worldwide in cross-disciplinary R&D projects and technical investigations.

NKT connects a greener world with high-quality power cable technology and takes centre stage as the world moves towards green energy. NKT designs, manufactures and installs low-, medium- and high-voltage power cable solutions enabling sustainable energy transmission. Since 1891, NKT has innovated the power cable technology building the infrastructure for the first light bulbs to the megawatts created by renewable energy today. NKT is headquartered in Denmark and employs 6,000 people. NKT is listed on Nasdaq Copenhagen and realised a revenue of EUR 3.3 billion in 2024. We connect a greener world.