PhD Research Project

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Development of New Materials for Additive Manufacturing (with BASF)

Institution:

University of Sheffield

Dept/School/Faculty:

Department of Mechanical Engineering

PhD Supervisor:

Dr C Majewski

Application Deadline:

Applications accepted all year round

PhD Research Project

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Additive Manufacturing (AM) involves the manufacture of parts, using a variety of materials and methods, without the requirement for any form of tooling. Major benefits of these technologies include the capacity to produce highly complex geometries (often allowing the complete redesign and optimisation of existing products), assemblies of moving parts, and the ability to produce customised products for no additional cost.

AM has demonstrated the potential to radically transform the manufacture of commercial products, and is of increasing interest in sectors as wide-ranging as automotive, aerospace, medical , consumer products etc.

Parts are produced directly from a Computer Aided Design (CAD) model. The CAD model is sliced into discrete cross-sections, and the solid part is built up one layer at a time, using an appropriate AM process.

Of the AM processes available, sintering technologies 6(where a focused laser is used to solidify powder) are the most promising for commerical activities. For metal processing, sintering technologies are already competitive with traditional manufacturing technologies, and the development of a wider range of polymer materials specifically designed for these processes will dramatically increase industrial uptake in this area.

This 3 year PhD will be sponsored by BASF Polyurethanes GmbH (http://www.polyurethanes.basf.com/), a subsididary of BASF SE, the leading chemical company worldwide. During your research studies you will have the opportunity to visit the global research team of BASF Polyurethanes GmbH to gain a basic understanding of thermoplastic polyurethanes (TPUs), as well as the global headquarters of BASF SE, the largest integrated chemical production site in the world.

The research will evaluate TPUs, a group of highly versatile elastomers, on their suitability for selective sintering processes. You will work with a team from BASF to test different TPU grades and elucidate relationships between chemical properties and process parameters that are critical for successful sintering of the material. You will supervised by academics from the University of Sheffield who are recognised as global leaders in the field and who have extensive experience of conducting industry-focused research and development.

You will be expected to develop a basic understanding of polyurethane chemistry, and to gain a detailed knowledge of the polymer Laser Sintering process, with relevant material analysis and testing techniques. Over the course of your studies you will develop and refine your own theories and methodologies regarding the requirements for TPUs for the LS process.

To be successful in your application you should have, or be expected to obtain, a 1st class or high 2:1 degree in mechanical or materials engineering, or a related discipline. In addition you will be enthusiastic, self-motivated , and possess excellent project management and communication skills.

The start date for this studentship will be agreed once we have identitified the best candidate for the position.

For an informal discussion regarding this studentship, please contact Dr Candice Majewski: c.majewski@sheffield.ac.uk.

Funding Notes:

The studentship includes funding of tuition fees at home rates plus a tax-free stipend (amount to be confirmed). Applicants from outside the UK/EU will only be considered if they are ready to pay the difference between student fees at home and overseas rates themselves.

Research Assessment Exercise (RAE) 2008 Results

Unit of Assessment: Mechanical, Aeronautical and Manufacturing Engineering				What is the RAE?
FTE Category A Staff Submitted	4*	3*	2*	1*	U/C
30.2	30%	45%	20%	5%	0%

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