PhD in improving the sustainability of polymer Additive Manufacturing/3D Printing (MEC-01-Majewski)

Details

This PhD project is focused around improving the sustainability of polymer Additive Manufacturing (3D Printing) processes

Project reference code: MEC-01-Majewski

Since their initial development for use for quicker and cheaper production of prototypes, Additive Manufacturing (AM) processes, often referred to as 3D Printing, have developed to be suitable for production of end-use parts, with service providers reporting that 33.7% of parts they produce are for end-use applications. Despite a general slowdown of the manufacturing industry caused by the COVID-19 pandemic, the worldwide revenue for AM products and services grew by 19.5% in 2021, to a total of $15.244 billion.

Powdered-polymer AM processes (e.g. Laser Sintering, High Speed Sintering, MultiJet Fusion, and Selective Absorption Fusion) which involve the melting and subsequent solidification of successive cross-sections of polymer powders, have become increasingly interesting to industry. Powdered-polymers now make up the highest proportion of AM material revenue, capturing 34.7% of the $2.598 billion global AM materials market in 2022. However, despite this increased uptake in powdered-polymer AM, the range of different materials is currently highly restricted, with nylon-12 making up the vast majority of the total commercially available materials. In order to expand the capabilities of these processes, it is common practice to mix or blend additional ‘filler’ materials into the base polymer, to introduce different properties. Examples include fillers aimed at increasing stiffness, providing flame retardancy or producing parts with anti-bacterial functionality.

While these fillers provide many benefits in terms of the range of part properties which can be produced, the use of multiple materials within the same powders and parts lead to greater complexity in recycling and/or re-using them. Un-melted powders recovered from the AM processes, or parts which are no longer needed, are significantly more difficult to recycle or re-use than their single-material equivalents. 

Your PhD will involve the development and optimisation of one or more techniques to transform waste powder and parts into a useful form or forms for re-use in future manufacturing applications. You will learn to use a variety of characterisation, testing, and manufacturing techniques, while also developing your research, communication and project management skills. You will also have the opportunity to be involved in teaching and Outreach activities relevant to your interests.

How to apply

Applications should be made through the University of Sheffield on-line submission system and select code MEC-01-Majewski. https://www.sheffield.ac.uk/arpform/login.app?code=EPSRC

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 (contact Candice Majewski, [email protected] or Patrick Fairclough, [email protected]). Please refer to the EPSRC DTP webpage for detailed information about the EPSRC DTP and how to apply.