Prof. Dr. Thomas Mayer
Prof. Dr. Thomas Mayer
ZHAW
School of Engineering
Institute of Mechanical Systems
Technikumstrasse 9
8400 Winterthur
Work at ZHAW
Position
Head of Focus Area Mechanics for Modelling, Senior Lecturer in Mechanics
Focus
- Thermo-Mechanical Process Simulation (e.g. for Additive Manufacturing)
- Material Characterisation & Modelling (Metals)
- Modelling of Damage & Lifetime Prediction (Metals)
- Thermo-mechanical FE Simulation & Structural Optimisation
Teaching
- Senior Lecturer in Mechanics, BSc Mechanical Engineering
- Lecturer in Mechanics, MSE MSc in Engineering
Experience
- R&D Engineer (Mechanical Components)
General Electric / Alstom, Switzerland
01 / 2015 - 12 / 2019 - R&D Engineer (Centre for Mechanical Integrity)
inspire AG
01 / 2012 - 09 / 2013 - PhD Student / Research Assistant
Empa - High Temperature Integrity Group, Switzerland
09 / 2008 - 08 / 2012
Education and Continuing education
Education
- Doctorate (Dr. sc. ETH) / Mechanical Engineering - Experimental and Structural Mechanics
ETH Zurich / Empa
09 / 2008 - 12 / 2012 - MSc ETH / Maschineningenieurswissenschaften - Mechanics, Structures, and Manufacturing
ETH Zurich
03 / 2007 - 09 / 2008 - BSc ETH / Mechanical Engineering - Structural Mechanics
ETH Zurich
09 / 2003 - 08 / 2007
Continuing Education
- Internal Leadership Course
ZHAW
09 / 2022 - CAS University Didactics
PHZH
09 / 2020
Network
Membership of networks
ORCID digital identifier
Projects
- Bobbin Tool and Process Monitoring for FSW for Lightweight Applications / Deputy project leader / ongoing
- Reduced Residual Stresses through Support Structure Optimization in Laser Powder Bed Fusion / Project leader / ongoing
- Development of an accelerated reliability test for innovative, lead-free power semiconductors / Project leader / completed
- Digital Twin of ROSTA Rubber Spring Elements / Deputy project leader / completed
- Machine Learning Enhanced Process Simulation in Laser Powder Bed Fusion / Project leader / completed
- Optimisation of additively manufactured metallic components with process simulation / Project leader / completed
Publications
Articles in scientific journal, peer-reviewed
- Hofmann, M. et al. (2026) 'Melt pool geometry and process windows in PBF of 316L : comprehensive single-source dataset and statistical modeling', Materials & Design, 262(115459). doi: 10.1016/j.matdes.2026.115459.
- Mayer, T., Friso, F. and Radis, R. (2025) 'Effect of build orientation on thermal expansion of LPBF printed Ti-6Al-4V', Metallurgical and Materials Transactions A, 56(4), pp. 1287–1309. doi: 10.1007/s11661-025-07706-7.
- Scheel, P. et al. (2023) 'A close look at temperature profiles during laser powder bed fusion using operando X-ray diffraction and finite element simulations', Additive Manufacturing Letters, 6(100150). doi: 10.1016/j.addlet.2023.100150.
- Scheel, P. et al. (2023) 'Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion', International Journal of Mechanical Sciences, 260(108583). doi: 10.1016/j.ijmecsci.2023.108583.
- Baertsch, F., Ameli, A. and Mayer, T. (2021) 'Finite-element modeling and optimization of 3D-printed auxetic reentrant structures with stiffness gradient under low-velocity impact', Journal of Engineering Mechanics, 147(7). doi: 10.1061/(ASCE)EM.1943-7889.0001923.
- Mayer, T. et al. (2020) 'Simulation and validation of residual deformations in additive manufacturing of metal parts', Heliyon, 6(5), p. e03987. doi: 10.1016/j.heliyon.2020.e03987.
Written conference contributions, peer-reviewed
- Hofmann, M. and Mayer, T. (2026) 'Towards accurate thermal simulations in PBF : a novel calibration strategy for Gauss-Goldak heat-source models', in 14th International Seminar on Numerical Analysis of Weldability, Graz, Austria, 21-24 September 2025. Winterthur: ZHAW Zurich University of Applied Sciences. doi: 10.21256/zhaw-35912.
- Eberlein, R. et al. (2026) 'Derivation of digital twins from high-fidelity simuliations of vulcanizates after multple cyclic loading', in Proceedings of 2nd CEACM Multiscale Modeling of Solids and Fluids Conference 2026. Budapest: Budapest University of Technology and Economics, pp. 92–96. doi: 10.3311/ceacmmsf2026-004.
- Mayer, T. et al. (2026) 'Modeling and simulation of the anisotropic thermal expansion of Ti-6Al-4V processed by PBF-LB/M', in 14th International Seminar on Numerical Analysis of Weldability, Graz, Austria, 21-24 September 2025. Winterthur: ZHAW Zurich University of Applied Sciences. doi: 10.21256/zhaw-35911.
Oral conference contributions and abstracts
Mayer, T. et al. (2024) 'Transformation induced anisotropic thermal expansion of LPBF processed Ti-6Al-4V', in 3rd Materials Science Colloquium, Lech am Arlberg, Austria, 15-18 April 2024.
Publications before appointment at the ZHAW
- Characterisation and modelling of the microstructural and mechanical evolution of a steam turbine rotor steel.
- A continuous Masing approach for a physically motivated formulation of temperature and strain rate dependent plasticity
- Parameter evolution in a continuous Masing approach for cyclic plasticity and its physical interpretation
- Dislocation density and sub-grain size evolution of 2CrMoNiWV during low cycle fatigue at elevated temperatures
- A Masing-type modelling concept for cyclic plasticity at elevated temperature
- A Masing-type modelling concept for cyclic plasticity at elevated temperature. Proc. Conf. on IUTAM Symposium on Advanced Material Modelling for Structures, Paris.
- The effect of sub-grain formation and development on cyclic response in engineering steels. Proc. Conf. on 18th European Conference on Fracture Dresden. DVM, pp. AA.02.01-O5.
- Mayer T., Davydov V., Holdsworth S. R., Lukás Strunz, P., 2010. Neutron diffraction examination of dislocation density evolution in a bainitic steel after low-cycle fatigue test at elevated temperatures. Eur. Conf. on Residual Stresses ECRS 8, Riva del Garda. Poster.