This vacancy refers to a PhD position in the framework of the Flemish ICON project Tesco (Temperature and geometrical Shape simulation and validation for FFF and FGF printed Components) on the topic of 3D printing (also known as additive manufacturing) using Fused Filament/Pellet Fabrication (FFF/FPF). The project is a close collaboration between the industrial partners of Deceuninck, Colossus, and HDM Engineering and the academic partners KU Leuven, TU Eindhoven, and Centexbel. This specific PhD topic concerns validating a physical model for the printing process and parts from the thermal and thermomechanical aspects. The ultimate objective is to obtain physics-based criteria to assist/optimise the printing.
Description of the organizational unit.
The promotor of the PhD will be Prof. dr. ir. Eleonora Ferraris from the AML group of the Mechanical Engineering Department, campus De Nayer (https://iiw.kuleuven.be/onderzoek/aml), KU Leuven. The co-promotor of the PhD will be dr.ir. Jie Zhang, of the same group. Upon successful completion of the PhD trajectory, the candidate will obtain a PhD degree in Mechanical Engineering at the Faculty of Engineering Technology of KU Leuven (http://www.kuleuven.be/kuleuven/).
Website unit
Project
Outline:
Fused Filament/Pellet Fabrication (FFF/FPF) is one of the best-known 3D printing techniques to produce thermoplastic components. It is based on thermal energy driven material extrusion and is used to manufacture parts with complex, unique geometries in small series, as well as in large volumes. In the Advanced Manufacturing Lab (AML) of KU Leuven, campus de Nayer, a thermal model to predict and simulate the build temperature of FFF/FPF printed parts based on the geometry, material and process has been developed [doi:10.1007/s40964-022-00271-0] and validated under various conditions. This PhD will go a step further from predicting temperature, to predicting bond quality and part performance as well.
Content:
The objective of this PhD is, first of all, to build up relevant expertise and gain physical insights in the dependence of the print quality (bond strength, part deformation) on the chosen process and design. The second objective is to give input to and experimentally validate a physics-based multiscale model (made by a colleague) of the printing process and parts from the thermal and thermomechanical aspects. The thermal aspects are experimentally studied using in-situ thermal monitoring with existing equipment (thermography at a spatial resolution of 31 µm/pixel). For the thermomechanical aspects, printed part deformations and bond strengths will be measured for different processes and designs. Dedicated printing experiments, based on isothermal as well as non-isothermal processes, will be designed to validate the bond quality (morphology and mechanical strength) of the resulting printed parts. Interfacial tension and/or shear experiments on macro parts with uniform bond quality and/or on single-strand samples, will be used to reveal the degree of bond healing, characterising the mechanical bond strength .
Profile
- A Master's degree in Science or Engineering with a background in Mechanical Engineering, Material Engineering, Applied Physics, Aerospace Engineering, Chemical Engineering or an equivalent Master’s degree.
- The candidate preferably has a background both in Manufacturing and modelling, but eagerness to learn is certainly just as important. Understanding thermal transfer mechanisms is considered an added value.
- Graduation with distinction is a requirement to start the PhD
- Hand-on experience with experiment equipment (e.g., hardware, mechanical test, thermography) is preferred
- Expertise in additive manufacturing with a focus on fused filament fabrication (FFF) is a plus.
- Being fluent in English (both speaking and writing) is a must
- You are creative and a team worker
- You are curious, and application driven with an interest in science and technology
Offer
- Ph.D. fellowship for the duration of a maximum of 4 years at a competitive salary.
- A challenging project with a very large industrial valorisation potential
- A multidisciplinary training and international working environment
- A highly valued academic environment and multi-cultural working group
Interested?
For more information please contact Prof. dr. ir. Eleonora Ferraris, tel.: +32 16 37 28 84, mail: eleonora.ferraris@kuleuven.be or Mr. Jie Zhang, tel.: +32 15 68 81 00, mail: jie.zhang2@kuleuven.be.
You can apply for this job no later than April 30, 2024 via the online application tool of the KU Leuven.
Please, provide your CV, motivation letter, and transcripts. Highlight in your CV the relevant expertise matching the demanded background as described above. Hence, indicate your knowledge in FFF and/or filament extrusion and/or numerical modelling. Also, indicate how you have distinguished yourself during your academic career until now. Clearly list your GPA (and GPA ranking if available), your (journal) publications as first author, talks or research grants/scholarships, if any.
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