Development of prototype product print manufacturing capability

Please note that this is an Engineering Doctorate and not a PhD - you will be based at the sponsor premises in Malmesbury.

The Research will be concerned with developing novel ceramic processing capabilities where manipulation and control at the nano/micro scale has a dramatic impact on the performance of the final product. There exist multiple critical areas (see below) each linked by a common set of materials challenges. Reflecting the dynamic nature of the organisation the themes continually evolve and the research engineer will be expected to contribute to, and help shape the development of, all of them to various degrees with at least one of the areas being their primary area of focus.

Bonding of ceramics to metals
Making a strong mechanical joint between a metal and ceramic is very challenging due to the mismatch between the thermal expansion coefficient between metals and ceramics. A range of processes are possible. Additives in the ceramic sintering process may help. Surface treatments may make adhesion better. Various bonding process could be considered although brazing is currently favoured. This project will look at developing or optimising a joining method for some combinations of materials which appear useful to Dyson. It will also look at characterising the quality of the joint from a thermal and mechanical perspective. Finally we would like to develop a theoretical understanding which underpins experimental findings. In all this, we will need to consider how process could be applied in a manufacturing environment.

Functionalisation of ceramics through doping
Dyson wants to complete an investigation we have already started looking at novel doping combinations to modify the electroceramic and thermo-mechanical properties of a commonly used industrial ceramic. The work will involve preparation of raw ceramics with dopants, characterisation of the green state ceramic, and studying the effect of sintering profiles on the electric and mechanical properties of the sintered piece.

Green state processing for novel geometries
Various methods exist to manipulate ceramics in their green state. Dyson has some unique applications where we seek novel part geometries. We are seeking some ways of forming ceramics into these shapes in the green state. The process must be compatible with the typical mass manufacturing processes for the ceramics we are considering. Considerations of dimension tolerance and mechanical integrity of the final component are important.

The Research Engineer will have a prototyping focus which requires both theoretical and practical knowledge of technical ceramics which serve an electrical, magnetic or dielectric purpose. Home to our global Research, Design and Development centre and all of our Commercial functions, Dyson HQ is tucked away in countryside famous for the railway tunnels and bridges of Isambard Brunel, who revolutionised modern engineering. Our secluded location helps us to protect our ideas and stay independent-minded. Yet nearby are the fashionable cities of Bristol and Bath (where a young James Dyson invented cyclone technology).