I have a general interest in Additive Manufacturing with my specific focus on the development of computational design tools including the use of lattice structures, topology optimization and the development of efficient computational approaches for the generation of structures.
My current experimental research focus is on the fabrication of multi-material metallic and metal-matrix composites (MMCs) targeting applications in Aerospace/Defence for reduction in SWaP (Size Weight and Power). Multi-material metal AM remains in its infancy but will lead to the ability to create multi-functional structures in demanding applications (high performance thermo-mechanical applications and energy storage). Additionally, the ability to deposit multi-materials has the potential for functionally graded materials (FGMs) that exhibit heterogeneous material properties spatially in 3D, but the ability to design meta-materials such as morphable structures via the use of multi-material topology optimisation techniques.
This research will build upon the use of a newly commissioned multi-material Aconity system available at CfAM, University of Nottingham, which features state-of-the-art dual-recoater Aerosint system. I am currently investigating alternative approaches to feedstock generation and new approaches to processing for the fabrication of multi-material AM parts.
DSTL Project (July 2023 – Nov 2024)
A project lead by Dr Anil Bastola, an investigation into 3D printing of programmable material jetting of magnetic composite elastomers and multi-materials will be investigated. The aim is develop a manufacturing technique for programming the magnetic domain of materials to produce shape-morphing structures targeting defence applications.
ASSAM – AI Synthesis of Structures for Additive Manufacturing (Nov 2022 – Nov 2024)
With fellow colleagues Dr Leijian Yu, Dr. Ian Maskery, and Prof. Ender Özcan, the project was successfully awarded on the UKRI New Horizons scheme for exploring the potential of Generative Approaches for synthesis (generation) using Deep Neural Networks for the design of novel structures extracted from nature that can be manufactured using 3D Printing. The collaboration at this stage extends into Computer Science, bringing AI tools such as VAE’s and GAN’s but also sourcing data from structures naturally occurring in nature such as foams, bone, fractal patterns
- 2023 – University of Nottingham – UNICAS Funding – 3D Printing Reinforcement in Civil and Structural Engineering Applications
- 2023 – Funded Project on Royce Undergraduate Research Internship Scheme [link] – High-energy ball-milling chosen for existing alloy and elemental powders process using in metal AM
Previously, I was a Research Fellow on the QUADPORS project at the University of Nottingham. QUADPORS a multidisciplinary collaborative project between partner Universities to investigate the use of multi-material Additive Manufacturing porous structures to reduce acoustic emissions and improve aerodynamic performance on aerofoils. The project focuses on the use of multi-material ‘4D Printing‘ of ‘smart materials’ for the creation of novel self-actuating and self-sensing programmable structures that have the ability to respond to external stimuli autonomously and extrinsically to achieve a change in its properties. The project will utilise low & high viscosity inkjetting techniques to deposit multi-materials to deposit a structures that can respond to external environmental stimuli.
Previous work built upon the generation of code for automatically generating the laser scan paths in the build files for Selective Laser Melting and using non-linear thermo-mechanical models to predict the development of residual stress generated during the process. Investigations included the role of laser scan strategy and laser parameters on the melt-pool geometry and the overall distribution of residual stresses within a scanner area. An alternative multi-scale approach was investigated as an alternative approach to common inherent strain methods used in commercial software. Further information on this may be read in doctoral thesis.
Following my doctoral studies, and boat-building, I was involved in investigating different computational techniques and approaches for the generation of micro-lattices. This included developing some computation models to predict the performance of lattices.
I am searching for potential high-calibre PhD candidates who are interested in pursuing the following themes.
- Computational design of structures for Additive Manufacturing
- The design and manufacture of multi-metallic and functional materials using L-PBF
Additionally, I am open to international collaborations and long-term academic visitors in relevant areas from researchers. These positions will required to be self-funded or through international exchange schemes. For relevant research topics I will support development of project proposals to aid submission to grant bodies.
Please get in-touch via my academic email address to discuss further. Before getting in contact regarding positions, please consider researching the group’s activities, research via publications and consideration for proposing your project ideas.
I frequently contribute to reviewing Journal Jrticles covering topics related to Additive Manufacturing with focus on Finite-Element thermo-mechanical process modelling, residual stress, L-PBF , DfAM, Lattice Design and their Simulation. I have been requested to support reviewing across the following Journals: