Additive manufacturing of functional materials for electrical machines

With the planet facing an environmental crisis, and a target to hit net zero by 2050, innovative research is needed to achieve our targets. To decarbonize our airways, we need high power density, efficient and fault tolerance electrical machines.

 Additive manufacturing has impacted many industries, but its use in electrical machines is still limited, despite a wide scope for improvements. This PhD project will focus on exploiting the power of additive manufacturing to deliver high performing functional materials to allow increases in performance of electrical machines. Both soft magnetic materials and conductive materials are required for electrical machines, and additive manufacturing can process them both successfully and with performance benefits such as reduced eddy current losses, higher slot fill factors and complex cooling integration. However one of the issues preventing additive manufacturing being utilized more is the surface roughness of the components, which can affect resistivity and loss behaviour.

This PhD project aims to improve the surface finish and hence the functional material properties of parts manufactured with additive manufacturing, by studying improvements in both the as-built condition using process control and by post processing. The impact of this will then need to be quantified on both a materials level, but also on a machine level. This will be an enabling technology for increasing the power density of electric machines to power electric aircraft. 

This PhD project will offer an exciting experience with hands-on use of metal additive manufacturing, along with the development and build of demonstrator materials and/or motors. A degree in Mechanical/Electrical Engineering, or Materials Science would provide the correct background for this role.

 Queries and CVs/covering letters from home students can be directed to the primary supervisor, Dr Alexander Goodall at a.goodall@sheffield.ac.uk

Start date: September 2025

How To Apply

Applications should be made at: PhD study nearmejobs.eu MAC nearmejobs.eu The University of Sheffield

Applications should include:

–              Personal statement

–              Curriculum Vitae

–              Two reference letters

–              Degree transcripts to date