High-Performance Laser Powder Bed Fusion of Polymer Parts Using Quantum Cascade Laser Arrays (EEE-30-Groom)

Details

This PhD will involve conducting research that will enable the next-generation of additive manufacturing processes based on the application of novel semiconductor optoelectronic components. Additive Manufacturing (AM) (often referred to as 3D Printing) processes provide many benefits in terms of geometrical complexity, material usage and flexibility, but are often inefficient with respect to energy and material usage, and remain restricted in terms of the range of materials that can be processed.

Photonics is a key enabling technology for a wide range of applications and finds its way into many aspects of modern life including communications, healthcare and high-value manufacturing. However, the choice of a photonic system in a manufacturing process is often based on an inventory of available products rather than being realised through partnerships to establish the process requirements and designing of an appropriate solution. By adopting an approach based on optimal system needs, this research topic brings together expertise in semiconductor optoelectronic devices, novel optical systems and laser powder bed fusion processes in order to develop AM systems that are tuned specifically to the needs of the material being processed. Our vision is to create the next generation of functional, reliable, and environmentally sustainable techniques for manufacture of high quality, high value printed parts.

The technique, pioneered in Sheffield, uses dense arrays of semiconductor lasers at wavelengths matching the peak absorption of the material being processed. This efficient, scalable, high-speed parallel processing of powdered feedstock benefits from precise control over material microstructure and offers improved part functionality in a wide range of applications.

You would have the opportunity to gain expertise in a range of associated themes including the design and customisation of optoelectronic components and integrated optical systems, in-situ process monitoring through advanced radiation thermometry, and control system optimisation, as well as microstructural characterisation of printed parts. The Studentship will be based primarily within Electronic & Electrical Engineering, but depending on the main focus of the PhD they will work in partnership with colleagues across the Engineering Faculty, further broadening their skill-set.

Furthermore, the instrument uses mainly off-the-shelf components for printing metallic parts but it may also possible to engage in semiconductor device development to extend the technology into the mid-infrared for manufacture of polymer parts. For this, you can make use of our own extensive facilities for semiconductor materials growth, device fabrication and characterisation.

We are seeking highly motivated candidates with a background in electronic engineering, materials science, physics, or a related field. A strong interest in laser based additive manufacturing is essential, together with an interest in semiconductor optoelectronics, photonics, and/or control systems engineering.

Interested candidates are strongly encouraged to contact the project supervisors to discuss your interest in and suitability for the project prior to submitting your application.

Please refer to the EPSRC DTP webpage for detailed information about the EPSRC DTP and how to apply.

Apply Here: Application Form (sheffield.ac.uk)