CDT-GIF: Innovative Modular Tooling for Reducing Consumables in Carbon Fibre Reinforced Polymer (CFRP) Manufacturing

This advert will close once a suitable candidate has been found.

This PhD is one of a number of projects hosted by the Centre for Doctoral Training in Green Industrial Futures (CDT-GIF). We are offering pioneering research projects that will enable PhD researchers to explore key technologies and solutions that will support UK industry to reach net zero.

Project: The carbon fibre reinforced polymer (CFRP) industry is crucial to many advanced sectors due to its high strength-to-weight ratio and durability. However, the manufacturing process involves significant use of consumables, particularly single-use items like vacuum bags and tacky tape, which contribute to both material waste and increased costs. This project aims to address these challenges by developing new modular tooling technologies using silicone sheets, which will replace traditional consumables in processes such as resin infusion. The research will explore the feasibility of creating reusable, adaptable silicone-based tooling system that allows for precise moulding to drastically reducing single-use consumables. The project will focus on both the performance of these modular systems and the practical integration into existing CFRP production lines. By eliminating disposable components, this innovation has the potential to significantly reduce the environmental impact of CFRP manufacturing. A key part of this study will involve re-evaluating the Life Cycle Assessment (LCA) of CFRP manufacturing, with a focus on how reducing consumables impacts the overall environmental and economic footprint. This work will not only reduce waste and costs in the manufacturing process but also offer an innovative solution to support industries in achieving their sustainability and decarbonisation goals.

Supervisors: Dr Tim Harrell and Dr Fulvio Pinto 

CDT in Green Industrial Futures: The CDT is funded by the UK Engineering and Physical Sciences Research Council and is a partnership between Heriot Watt University, Imperial College London, and the Universities of Sheffield and Bath. The CDT is further supported by contributions from industrial partners. Bringing these leading universities together allows CDT-GIF students access to a wide range of academic expertise, resources and facilities.

The CDT-GIF has an exciting and challenging programme specifically designed for top performing junior researchers. Alongside the four-year research project, students will receive expert training and opportunities to contextualise their research within the wider net zero landscape, including:

• Residential taught courses at each of the partner universities in Years 1 and 2 that provide training in the systematic considerations for industry including: Life Cycle Analysis (LCA), technoeconomics, business models, policy & regulation, public engagement, plant operation.
• An international opportunity in Year 2 or 3 of the programme, including opportunities to visit a world-leading facility, conference or forum and explore the global context of industrial decarbonisation.
• A work placement with one of our industrial partners.
• A bespoke ‘net-zero leadership programme’, including regular exchanges with cohort members from the other universities, student-led activities, industry challenge sandpit, industrial site visits, and professional development opportunities.

Candidate requirements: As a minimum we require candidates to have a First-class or 2:1 Meng, MSc, or MA with merit (over 60%) in a relevant area i.e. Mechanical Engineering, Process Engineering, Chemistry, Materials Science, Geoscience. Applicants who have a First-class BSc/BEng (Hons) and can demonstrate significant relevant industry/research experience may also be considered.

Non-native English speakers must ensure they meet the English language requirements.

Enquiries and applications. Informal enquiries regarding the research project can be directed to Sophia Coe sc3716@bath.ac.uk. Alternatively, if you have a question regarding the wider CDT-GIF programme, please contact cdtgreenindustrialfutures@hw.ac.uk .

Formal applications can be made here: https://greenindustrialfutures.site.hw.ac.uk/the-programme/how-to-apply/ Applications are open until filled so we would encourage early application.

The initial application involves an application form (including a short personal statement and CV). You may select up to two CDT-GIF projects. Applicants will then be selected to interview. If successful at interview, candidates will be asked to complete the application process for the home university.  

Equality, Diversity and Inclusion. We warmly encourage applications from individuals of all backgrounds, experiences, and perspectives. Our programme values diversity as a cornerstone of innovation and collaboration, and we are committed to creating an inclusive environment where everyone feels respected, supported, and empowered to thrive. The CDT-GIF are committed to ensuring flexibility throughout our programme to support student’s needs and personal circumstances, for example those with medical conditions, caring responsibilities and other considerations. For example, we are open to exploring part-time options if appropriate for the nature of the research. 

Keywords: Carbon Fiber Composites; Manufacturing; Reducing single-use consumables; Modular Tooling; Sustainability