Generic methodology to determine quality assurance and validation processes for additively manufactured parts.

Additive Manufacture CDT Project at University of Nottingham supported by Exova/NPL

The emergent use of additive manufacturing (AM) and 3D printing technology for the manufacture of end use products requires the development of significant supporting methodologies and additional tools. Among these requirements is the provision of suitable metrology approaches underpinning testing, certification and quality assurance procedures. This is seen to be of particular relevance for the use of AM in safety critical applications, for example in the aerospace industries.

The scope of this project is to evaluate the current trends in polymer additive AM (through jetting, extrusion or sintering routes) and determine the applicability of international standard test methods for assessment of mechanical properties and failure of polymers and polymer composites generated from the AM processes. Defining the process modelling input, quality assurance through the manufacture process and validation requirements will direct the requirement for test method and outline the challenges.

Business benefits:

Additive Manufacturing (AM) is seeing increasing acceptance as a production technology for high value manufacturing, especially in aerospace and medical implants, enabling more complex and higher performance parts to be made more quickly than with conventional techniques. However, there are a number of barriers to its wider adoption in the UK which are being identified in the forthcoming UK AM Strategy. These will include the challenges of validating parts and the lack of agreed testing standards. This program of work would allow Exova collaborating closely with NPL to support the industry addressing the challenges as these become more apparent. Developing validation and definition of appropriate test methods to help the industry understanding the AM material behaviours with the industry will allow Exova to be the supplier of choice and have an input on the standardisation of methods. The close collaboration with NPL is strengthening our collaboration and is mutually beneficial.

The University of Nottingham hosts the world leading Additive Manufacturing and 3D Printing Research Group which has access to one of the most comprehensive Additive Manufacturing laboratory facilities worldwide.

Students receive funding for a full EPSRC studentship for 4 years. Companies provide additional top up to the project of a minimum of a third of the EPSRC funding. The student must spend at least three months at the company, and the company pays any travel and subsistence costs.

The successful candidate will:
• Receive the training needed for a professional career in 3D printing and related metrology
• Work directly with leading academics and industrialists
• Receive a studentship, covering UK/EU tuition fees and stipend
• Travel and consumable allowance
• Industrial sponsor contribution of £30,000 for extra allowance on travel, consumable and stipend enhancement

Eligibility

You must possess a minimum 2:1 in Engineering or Physical Sciences related discipline.
Due to funding restrictions, studentships are currently only available for those eligible to pay UK/EU tuition fees.

How to apply

Please send a copy of your CV, academic transcripts and a covering letter detailing your research interests to [Email Address Removed].

The successful candidate will be available to start in October 2016.