PhD Studentship: Development of a Bespoke Extrusion Based Additive Manufacturing Capability for the Production of Functionally Graded Multi-material Components

The Manufacturing Technology Centre (MTC) and University of Birmingham’s School of Chemical Engineering are offering a co-funded PhD, giving applicants in engineering and physical sciences the opportunity to study alongside world-leading academics. The MTC is an independent Research and Technology Organisation (RTO) aimed at de-risking and accelerating the adoption of disruptive technologies within the UK manufacturing sphere. Supported by the UK government, the MTC works closely with industrial partners and other research organisations to deliver world leading innovation.

As a researcher at Birmingham, you will benefit from working in an environment in which excellence and innovation are made possible by brilliant people, outstanding facilities and strong collaborative networks. You will be joining a global top 100 university tackling some of the biggest issues the world faces, making a difference to people's lives.

This is a 3-year fully funded studentship, the successful applicant will receive a tax-free annual stipend of £25,000 plus payment of their full-time home tuition fees. Additionally, £2,000 per annum is provided for consumables, travel, etc. Successful candidates need to pass the sponsors own security checks prior to the commencement of the project.

This project will focus on the development of a novel prototype additive manufacturing capability to address conventional challenges associated with joining of similar, dissimilar and multi-material systems. With an aim to manufacture bespoke functionally graded microstructures through in situ co-processing of materials specifically tailored to provide enhanced performance, extend component in service life and improve resource efficiency. This will harness the dispersive and distributive compounding capability of screw extrusion technology, combined with the well-established advantages of conventional material extrusion based additive manufacturing.

The project will require a structured approach to develop an in depth understanding of compounding effects on the interactions of powder-binder systems at the microstructural level, focusing on the following aspects:

• Downselection of candidate multi-material systems that are processable via additive manufacturing extrusion (MEX) and shape-debind-sinter (SDS) methodologies
• Concept design leading to prototype development of novel additive manufacturing capability based on screw extrusion technology
• Material property characterisation of formulated powder-binder systems to assess manufacturing process compatibility
• Benchmarking of prototype capability via parameter optimisation through exploration of the process envelope
• Evaluation of microstructural integrity of thermally post processed material systems with particular emphasis at the functionally graded interface
• Assessment of geometric fidelity, dimensional accuracy and fine feature resolution

The successful applicant will be self-disciplined, resourceful and have a strong passion for creating impact by solving industrial problems. The student will be required to develop a working knowledge of mechanical and materials engineering principles. Specifically, mechanical design and advanced microstructural techniques such as powder characterisation as well as in depth thermal, mechanical and rheological testing. The PhD candidate will be based in the School of Chemical Engineering in the University of Birmingham, with most laboratory work conducted in the ceramics forming laboratory in the School of Metallurgy and Materials, with some specialist activities being undertaken at the MTC.

Funding Notes: 

To be eligible for EPSRC funding candidates must have at least a 2(1) in an Engineering or Scientific discipline or a 2(2) plus MSc. 

Open to UK nationals only due to funding restrictions.

Please contact Dr Alex Cendrowicz (a.cendrowicz@bham.ac.uk) or Adam Edwards (adam.edwards@the-mtc.org) 

Proposed PhD Start Date: 1st October 2025.

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