FAV graduate won an international thesis competition for its practical impact

Time saved in the development of parts, fewer scraps, and lower costs for prototypes made of steel sheets. All this can be achieved with a properly configured computer model. Adam Hybler describes this in his thesis, for which he received the top award in the NAFEMS Student Award competition.

Adam Hybler studied Applied Mechanics at the Faculty of Applied Sciences of the University of West Bohemia in Pilsen, with a specialization in Structural Dynamics and Mechatronics. He graduated in June 2025. He entered the NAFEMS Student Award competition at the suggestion of one of his employers, with the recommendation of his thesis supervisor, Martin Zajíček, head of the Elasticity and Strength Department at the Faculty of Applied Sciences. Every year, the international non-profit association NAFEMS (originally the National Agency for Finite Element Methods and Standards) holds a competition to recognise the very best work of Engineering Simulation Students. The aim is to encourage young talent to remain in the field and find employment, as well as to raise the status of education in this field. This November, the jury selected the work of the Pilsen graduate Adam Hybler as the best. In addition to first place, he also received a financial reward and the opportunity to present his work at a regional conference in Budapest next year.

Adam, what exactly did you focus on in your thesis?

I investigated how accurately we can use computer simulations to predict the behavior of sheet metal during forming, for example, in the manufacture of car body parts in the automotive industry. I focused on the fact that sheet metal does not behave the same way in every direction — in some places it stretches easily, while in others it offers greater resistance. This phenomenon is called anisotropy. At the same time, I also looked at how the material transitions from a flexible (elastic) to a permanently deformed (plastic) state. If the simulation describes these phenomena inaccurately, it will begin to predict behavior that differs from what actually occurs. In the laboratory, I therefore carried out tensile tests of the examined high-strength steel in several directions, created material models from the results, and then compared them with real behaviour. The verification was carried out using a deep drawing experiment – i.e., creating a cup from sheet metal, where the uneven height around the circumference is monitored. Based on this, it is possible to determine very accurately how significant the anisotropy of the material actually is and how well the simulation can predict it.

Did your work bring any new insights?

It was expected that the more advanced material model would be the most accurate. However, it turned out to be very sensitive to the quality of the input data, i.e., how accurately we know the properties of the sheet metal. If the data is even slightly inaccurate, the simulation results quickly deteriorate. On the contrary, a simpler model, which is commonly used and less computationally demanding, was able to produce comparable or even better results in some cases. The main finding is that it is not essential to have the most complex model, but to have well-measured and consistent material data. In practice, this means that it is possible to achieve comparable accuracy without the need for complex and lengthy calculations for the material under investigation.

Where can your results be used in practice?

The results can be applied wherever metal sheets are shaped. A properly configured model can save time in component development, reduce the number of scrap rates , and lower prototype costs. This allows companies to better decide when it makes sense to use a more complex mathematical description of the material and when a simpler approach is sufficient. At the same time, several methods of conducting the experiments themselves were compared.

You currently work for two different companies. What exactly do you do there?

I work for COMTES FHT, where I conducted material experiments and created simulation models related to my thesis while I was still a student. Currently, I also work in other areas, such as topological optimization related to 3D printing. At the same time, I work for IDIADA CZ, where I focus on simulations for automotive development. This allows me to combine research and experimental activities with the industrial application of simulation methods. I try to maintain a broad scope in the field of mechanical simulations, as the diversity of topics is my greatest source of motivation and inspiration.