1. A Master's degree in Science or Engineering with a background in Material Engineering, Chemical Engineering or Mechanical Engineering with an interest in Computer Science.
2. The candidate needs to have a background in modelling with interest in manufacturing and/or polymer processing. Understanding heat transfer mechanisms is considered an added value.
3. Graduation with distinction is a strict requirement to start the PhD
4. Proficiency in the programming languages for scientific computing such as Python, Matlab and/or C++
5. Expertise in additive manufacturing with focus on fused filament fabrication (FFF) is a plus
6. Being fluent in English (both speaking and writing) is a must
7. You are creative and a team worker
8. You are curious, and application driven with an interest in science and technology
Outline:
Fused Filament/Pellet Fabrication (FFF/FPF) is one of the best-known 3D printing techniques for the production of 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 for high volume production. In the Advanced Manufacturing Lab (AML) of KU Leuven, campus de Nayer, a predictive model for the build temperature evolution of FFF/FPF printed parts has been developed [doi:10.1007/s40964-022-00271-0]. This model, named T4F3 ‘Temperature for Fused Filament Fabrication’, has been successfully applied to simulate thermal evolution in products during the print process under various conditions. The model can be used to predict critical reheating temperatures and to optimise the print quality of PLA (polylactic acid) and other polymers parts.
In parallel, TU Eindhoven has developed Dawn, an advanced finite-element simulation framework designed to capture the mechanical behaviour, stress evolution and material-state development in layered, additively manufactured structures.
Content:
The objective of this PhD is to develop a multiscale model for part and process simulation including the implementation of mechanical bond-quality evolution. The key challenge lies in the coupling of the micro-scale polymer bond kinetics to the mesoscale bond strength and performance. To reach this objective, the KU Leuven T4F3 model will be integrated into the currently available Finite Element-based simulation environment of TU Eindhoven, which allows the mechanical analysis of print processes of larger parts, including thermal boundary conditions.
This framework will be extended and validated for free-form geometries and application-relevant shapes for industrial partners in the field of high-precision additive manufacturing for chip packaging, where thermal control and bond quality are critical to interconnect reliability. Bond development (kinetics, morphology, strength) will be investigated under isothermal and non-isothermal conditions above the glass-transition temperature of both amorphous and semicrystalline thermoplastics. Ultimately, the project aims to formulate a generalised theory of local bond quality for arbitrary temperature histories representative of FFF/FPF processing.
Complementary experimental work (executed by a collaborating researcher) will provide material- and process-level input for the model and serve as a basis for thorough validation.
This vacancy refers to a KU Leuven – TU Eindhoven joint PhD position in the framework of a Global PhD Partnership programme between the two universities on the topic of 3D printing (also known as additive manufacturing) using Fused Filament/Pellet Fabrication (FFF/FPF). This specific PhD topic concerns the development and integration of a multi-scale modelling environment, where expertise from both KU Leuven and TU Eindhoven needs to be combined. The selected PhD candidate will therefore have promotors from the two universities, giving an international dimension to the research. The location of work will be both KU Leuven, campus de Nayer, and Eindhoven University of Technology in alternating periods of one or two years. The promotors of the PhD will be Prof. dr. ir. Eleonora Ferraris (eleonora.ferraris@kuleuven.be, +3215316944) from the AML group of the Mechanical Engineering department, campus de Nayer, KU Leuven, Belgium (https://iiw.kuleuven.be/onderzoek/aml) and Dr. Ir. Joris Remmers, (j.j.c.remmers@tue.nl) from the section Mechanics of Materials of the Mechanical Engineering Department, TU Eindhoven, the Netherlands (https://www.tue.nl/en/research/research-groups/mechanics-of-materials/group-remmers). Upon successful completion of the PhD trajectory, the candidate will obtain a joint PhD in Mechanical Engineering at the Faculty of Engineering Technology of KU Leuven (http://www.kuleuven.be/kuleuven/) and at Eindhoven University of Technology (www.tue.nl).
9. Ph.D. fellowship for the duration of a maximum of 4 years at a competitive salary
10. A challenging project with a very large industrial valorisation potential
11. A multidisciplinary training and international working environment
12. A highly valued academic environment and multi-cultural working group