PhD Studentship: High Build Rate and Low Carbon Emissions Laser Direct Energy Deposition Additive Manufacturing via Advanced Laser-matter Interactions

This 3.5-year PhD is funded by the University of Manchester and is open to UK students. The funding covers the cost of tuition fees and a standard tax-free stipend (based on the UKVI rate which is £20,780 for 2025/26).

Direct energy deposition with a laser beam (DED-LB) additive manufacturing has generated substantial interest in diverse industrial applications due to its potential for fabricating complex metal structures. This opportunity is centred around improving manufacturing productivity with advanced laser-matter interactions control and optimisation. The PhD will advance our comprehension of the mechanisms that lead to defect formation in DED-LB, and improve process control measures to either prevent or mitigate the defects.

The additionality of external controls over the laser-matter interactions could increase the process build rate, and thus reduce carbon emissions, and uptake for this process across a wide range of sectors, offering solutions not possible by conventional manufacturing methods. However, there are significant challenges to a broad proof of concept that would be addressed in this PhD project. Laser beam sources, process development and control to enable better control of mass transfer and laser-matter interactions.

The “design-manufacture-inspect-model-test” approach of this project will equip the successful PhD candidate with a wide range of valuable and transferable skills. More specifically, to (1) identify the advanced laser-matter interaction controls by achieving an understanding of the underlying mechanisms, (2) optimise the process with online monitoring to ensure high consistency of quality, (3) use the knowledge gained to understand the opportunities and limitations of the process when extended to a wide range of wire and powder materials.

The PhD studentship is based at The Laser Processing Research Laboratory (LPRL) at The University of Manchester (UoM). The Laser Processing Research Centre was established on 1 April 2020 by Professor Lin Li as its director. The Centre sits within the Department of Mechanical, Aerospace and Civil Engineering at UoM and performs advanced modelling and technical innovations in the field of laser-based advanced manufacturing and synthesis of new materials. For the DED-LB additive manufacturing, the lab has a house-developed Laser-Kuka cell with a 16kW IPG laser and wire/powder feeding systems. The lead supervisor, Dr Yuze Huang, specialises in laser-matter interactions of metal additive manufacturing, and the co-supervisor, Professor Paul Mativenga (UoM), has extensive expertise in laser materials processing. Dr Chu Lun Alex Leung (Mechanical Engineering at UCL) will also collaborate. he specialises in imaging of additive manufacturing and will support the project by assisting with the in-process monitoring. We expect that the PhD candidate will also work closely with academic and industrial collaborators and research institutes, including the Photon Science Institute, BP International Centre for Advanced Materials (BP-ICAM), The University of Manchester at Harwell, and the Engineering & Physical Sciences Research Council-funded Henry Royce Institute for Advanced Materials.

• Prior experience in additive manufacturing, welding, and magnetic-assisted or ultrasonic-assisted manufacturing would be advantageous.
• Good oral and written communication skills with the ability to prepare presentations, reports and journal papers to the highest levels of quality.
• Good interpersonal skills are required to work effectively in a team consisting of PhD students and postdoctoral researchers.

To apply, please contact Dr Yuze Huang (yuze.huang@manchester.ac.uk). Please enclose the following documents:

• A one-page statement addressing your background and suitability for this project.
• A two pages CV

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