Development Of Fully Resolved Finite Element Model For 3D Printed Semi-Crystalline Polymers

  • Funded PhD opportunity
  • Computing, Engineering and the Built Environment
  • Full-time
Apply and key information  

This project is funded by:

    • Department for the Economy (DfE)

Summary

Fused Deposition Modelling (FDM) is one of the most widely used Additive Manufacturing (AM) techniques due to its capability to produce parts with complex geometries, ease of operation, and cost-effectiveness. Among the thermoplastic feedstocks for FDM, semi-crystalline polymers are gaining significant attention because of their exceptional mechanical performance in high-temperature environments, as well as their chemical and wear resistance. However, these polymers present unique challenges, including thermal shrinkage and warpage, which can compromise part quality.

At Ulster University, a cutting-edge in-house simulation model was developed to predict and analyse these phenomena, with an overall prediction accuracy of 82%. This model has been widely recognised within the research community, inspiring further similar studies in the field. Building on this foundation, this PhD project offers an exciting opportunity to advance the current framework by integrating polymer fluid dynamics during nozzle extrusion with existing thermal deposition and cooling models. The enhanced robust model will also incorporate mechanical testing of simulated parts.

In addition to computational modelling, the project encompasses hands-on experimental work, such as 3D printing of test samples, thermal characterisation of the polymer of study, and validation of simulation results through distortion measurements and mechanical testing. The resources required for this comprehensive study are available in-house at Ulster University.

This research is conducted within the renowned Advanced Future Materials and Manufacturing (AFM2) group, offering the successful candidate access to a world-class research environment. The project provides an exceptional opportunity to develop expertise in materials science, computational modelling, and additive manufacturing, paving the way to becoming a global leader in the simulation and application of polymers in FDM.

Essential criteria

Applicants should hold, or expect to obtain, a First or Upper Second Class Honours Degree in a subject relevant to the proposed area of study.

We may also consider applications from those who hold equivalent qualifications, for example, a Lower Second Class Honours Degree plus a Master’s Degree with Distinction.

In exceptional circumstances, the University may consider a portfolio of evidence from applicants who have appropriate professional experience which is equivalent to the learning outcomes of an Honours degree in lieu of academic qualifications.

  • Experience using research methods or other approaches relevant to the subject domain
  • A comprehensive and articulate personal statement

Equal Opportunities

The University is an equal opportunities employer and welcomes applicants from all sections of the community, particularly from those with disabilities.

Appointment will be made on merit.

Funding and eligibility

This project is funded by:

  • Department for the Economy (DfE)

These scholarships will cover tuition fees and provide a maintenance allowance of £19,237 (tbc) per annum for three years (subject to satisfactory academic performance).  A Research Training Support Grant (RTSG) of £900 per annum is also available.

To be eligible for these scholarships, applicants must meet the following criteria:

  • Be a UK National, or
  • Have settled status, or
  • Have pre-settled status, or
  • Have indefinite leave to remain or enter, or
  • be an Irish National

Applicants should also meet the residency criteria which requires that they have lived in the EEA, Switzerland, the UK or Gibraltar for at least the three years preceding the start date of the research degree programme.

Applicants who already hold a doctoral degree or who have been registered on a programme of research leading to the award of a doctoral degree on a full-time basis for more than one year (or part-time equivalent) are NOT eligible to apply for an award.

Due consideration should be given to financing your studies.

Recommended reading

  1. A. Antony Samy, A. Golbang, E. Harkin-Jones, E. Archer, and A. McIlhagger, “Prediction of part distortion in Fused Deposition Modelling (FDM) of semi-crystalline polymers via COMSOL: Effect of printing conditions,” CIRP J. Manuf. Sci. Technol., vol. 33, pp. 443–453, 2021, doi: 10.1016/j.cirpj.2021.04.012.
  1. A. A. Samy, A. Golbang, E. Harkin-Jones, E. Archer, D. Tormey, and A. McIlhagger, “Finite element analysis of residual stress and warpage in a 3D printed semi-crystalline polymer: Effect of ambient temperature and nozzle speed,” J. Manuf. Process., vol. 70, no. August, pp. 389–399, 2021, doi: 10.1016/j.jmapro.2021.08.054.
  1. A. A. Samy, A. Golbang, E. Harkin-Jones, E. Archer, M. Dahale, and A. McIlhagger, “Influence of Ambient Temperature on Part Distortion: A Simulation Study on Amorphous and Semi-Crystalline Polymer,” Polymers (Basel)., vol. 14, no. 5, 2022, doi: 10.3390/polym14050879.
  1. A. Antony Samy et al., “Influence of Raster Pattern on Residual Stress and Part Distortion in FDM of Semi-Crystalline Polymers: A Simulation Study,” Polymers (Basel)., 2022, doi: https://doi.org/10.3390/polym14132746.
  1. S. Schmid, “Fully Resolved Numerical Simulations of Fused Deposition Modeling,” pp. 1–5, 2016.
  1. H. Xia, J. Lu, and G. Tryggvason, “Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle,” Rapid Prototyp. J., vol. 24, no. 6, pp. 973–987, 2018, doi: 10.1108/RPJ-11-2017-0233.

The Doctoral College at Ulster University

Key dates

Submission deadline
Monday 24 February 2025
04:00PM

Interview Date
March 2025

Preferred student start date
15th September 2025

Applying

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Contact supervisor

Dr Anto Antony Samy

Anto Antony Samy

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