Our student projects

24/25 Cohort

25/26 Cohort

24/25 Cohort 

Lewis Griffin - High-Rate Manufacturing of Composite Wing Structures – sponsored by Airbus

High rate manufacturing poses a greater likelihood of scrapping materials or structures that do not meet quality standards. A previous project sponsored by Airbus showed that semi-cured interfaces enabled key properties to be maintained. Lewis’ PhD project will explore the potential to form semi-cured charges into complex shapes needed to reduce defects and optimise composite products. Sustainability is addressed by reducing scrap part, whilst also delivering effective emissions reductions through component design. The project involves:  

• Hands-on manufacturing of flat semi-cured charges to various degrees of cure, followed by forming.  
• Characterisation of the cure kinetics of the selected resin to support the design of the temperature cycle.  
• Quality assessment performed using state of the art instrumentation, including Laser CMM, X-ray CT and optical microscopy.  
• Key outputs will be forming strategies and material handling for industrial use. 

Finbar Carroll - Compression Moulding of Ceramic Matrix Composites (CMC) – sponsored by NCC

Fin’s EngD project investigates methods for reducing the cost of Oxide/Oxide CMC manufacture. The project considers how cost analysis, material substitution, new material systems, and advanced manufacturing methods can improve the scalability and commercial viability of Ox/Ox CMC components. The outcome will be a clearer manufacturing strategy for producing high-temperature CMC components more efficiently and cost-effectively. Sustainability is addressed through lightweighting of components, manufacture using less material and energy resulting in less scrap.

Torin Clark - Composite Hydrogen Storage Tank Process modelling – sponsored by Rolls-Royce 

Torin’s PhD project focuses on developing a numerical modelling approach to understand and predict the filament winding manufacturing process, specifically for applications like carbon-fibre reinforced hydrogen storage tanks. The project utilises advanced finite element models to simulate, inter and intra-laminar friction, compaction, and cure. The aim is to predict of manufacturing outcomes such as fibre orientations, part thickness and likelihood of wrinkling, and use these to inform structural performance models of tanks. By understanding defect generation at the modelling stage less material will be used by creating a more efficient structure.

Priyanka Patel - Filament Winding of non-oxide CMCs (Ceramic Matric Composites) -  sponsored by NCC 

Priyanka’s EngD project investigates automating manufacture of CMCs using filament winding technology to minimize costs, whilst creating more consistent materials. NCC have previously demonstrated AFP deposition of oxide CMCs, but non-oxide CMCs significant technical challenges. The project focuses on formulating and testing non-oxide materials that will be a UK first to be fully utilised in wet filament winding processes which is capable of operating at temperatures of around 3000°C, and will create wide industrial impact. This work will aim to support sustainable composites engineering by improving aero-engine efficiency and progressing nuclear fusion energy production. 

Desmond Li - Improved design and damage tolerance of lightweight composite sandwich structures

The key design drivers for the adoption of sandwich structures include high specific stiffness and strength, damping, thermal insulation and excellent fatigue properties by adopting constituents and tailored geometric layouts. Desmond’s PhD project will: 

• Develop and commission new structural scale sandwich panel test:  realistic bi-axial, including in-plane and bending loads, quasi-static 
• Develop a finite element-based modelling methodology (fracture mechanics / Cohesive Zone Modelling (CZM)) to predict the onset and progression of skin/core debonding  
• Compare and validate the sandwich panel experiment 
• Develop and implement novel concepts for improving face-sheet / core resistance and benchmark against existing concepts / experimental validation, and modelling developed methodologies 
• Provide the next-generation of analysis/design procedures for efficient lightweight engineering structures to facilitate Net-Zero sustainability goals. 

Hendrick Esterhuyse - Characterisation and simulation of the effects of wrinkling defects caused during Non-Crimp Fabric (NCF) preforming

Hendrick’s PhD project investigates the impact of out-of-plane fibre waviness defects in fibre-reinforced composites, aiming to develop a validated experimental and simulation framework to support sustainable and defect-tolerant design. Fibre waviness, often introduced during preforming, consolidation, or curing, significantly reduces mechanical performance and remains challenging to detect and quantify. The project intends to address two key research gaps: the absence of standardised wrinkle acceptance criteria and the limited understanding of wrinkle interactions in larger-scale structures. The project objectives are: 

• Design and validate a repeatable, rig-assisted experimental framework for generating controlled wrinkle defects, enabling systematic study of defect formation and variability 
• Develop a high-fidelity finite element (FE) modelling approach to simulate the mechanical response of 3D composite components with embedded wrinkles. 
• Integrate the validated FE models into a multi-scale simulation framework, bridging microstructural features with macro-scale performance to support predictive design. 
• Deliver a next-generation simulation tool capable of modelling a wide range of fibre waviness magnitudes, enabling accurate prediction of defect-induced performance degradation. 
• Advance the understanding of defect tolerance in composite structures, contributing to the development of resilient and certifiable composite designs. 
• Promote sustainable composite manufacturing by reducing material waste, improving defect acceptance criteria and supporting intelligent design-for-manufacture strategies. 
• Creating multifunctional materials to provide a key development in sustainable transportation.  

Ryan Chung - Hybrid physics-based and data-driven models for the prediction of process-induced voids in advanced composites – sponsored by LMAT 

Composites are used for manufacturing aerospace, automotive, and renewable energy components. However, this surge in demand brings sustainability challenges, including the need to reduce waste and energy consumption during production. Addressing these challenges is critical as industries work to minimize their carbon footprints. Modelling reduces the need for trial-and-error in the manufacturing process, which reduces the material and energy waste. For example, in the wind energy sector, effective modelling can help optimize the quality of composite wind turbine blades, reducing defects such as voids, which are small air pockets that can compromise the material’s structural integrity. Ryan’s EngD project focuses on understanding the formation of voids, and developing a model to predict their formation. Ultimately, a predictive model will be created that integrates both physics-based and machine learning (ML) approaches. The end aim is to promote sustainability, by allowing faster modelling, enabling reduction in composite wastage. 

Jack Burns - Novel flexible photonic based sensors for health monitoring of composite structures

A radical redesign of optical fibre architecture has enabled a new in-situ measurement paradigm that elicits quantitative assessment of through-thickness strains in laminated composite structures during manufacture and service. The novel sensor technology will inform composite design and manufacturing strategies to facilitate Net-Zero sustainability goals by reducing scrappage and extending operational lifetime. Jack’s PhD project will investigate: 

• Design procedures that enable the flexible photonic sensor to make multiple measurements quickly with real time reporting on the health of the structure. 
• Develop the new sensors for both manufacturing control and service life predictions of a composite structure. 
• Devise new sensing methodologies as the basis for the creation of future sustainable composite products. 

Firat Ergin - Repeated impacts on composite aero-structures – sponsored by Rolls-Royce

Instead of continuously supplying heat to prevent ice from forming on the leading edge of turbofan engine nacelles, it can be more energy efficient to allow some ice to build up and then remove it using de-icing systems. This approach can improve engine efficiency and support more sustainable aviation. However, de-icing systems can sometimes shed large ice fragments, which may be ingested by the engine and cause high-energy impacts on composite fan blades. Whilst a single ice impact might not be critical, multiple impacts can lead to fatigue damage accumulation in composites. There is very limited research into repeated impacts, especially those occurring below the damage initiation threshold, hence Firat’s PhD project will address an unexplored gap in understanding. The project combines experiments and numerical modelling to:  

• Investigate repeated loading under low velocity to establish the material’s damage threshold and establish the threshold of initiation and evolution of damage.  
• Provide numerical damage models to predict the onset and progression of damage, as well as to understand the mechanisms and drives for damage development.   
• Undertake higher strain rate testing, via the use of a drop weight impactor and gas gun to provide understanding of potential rate effects, ensuring the research is relevant for real-world impact loading scenarios.   
• Establish impact fatigue allowables for composite component design, to unlock more sustainable and efficient aircraft designs with reduced engine power requirements. 

25/26 Cohort 

Sowmya Srinivasan - Application of Artificial Intelligence in Life Cycle Assessment of Composites Manufacturing – sponsored by NCC

Life Cycle Assessment (LCA) is a methodology increasingly used in industry for assessing the environmental impact of a product, process or service. Gathering comprehensive, accurate Life Cycle Inventory (LCI) data for different stages of a product’s life cycle can be challenging, as data can be incomplete, thus impacting the reliability of LCA results. Moreover, identifying the best impact assessment is subjective and can cause differing results for the same product. For composite structures, these effects are further compounded by decisions made early in the design process, such as fibre and matrix selection, geometry, and manufacturing processes. The implementation of IoT systems and artificial intelligence (AI)/machine learning (ML) techniques could potentially overcome these challenges, enhancing the precision, efficiency, and depth of environmental impact assessments, and allowing for LCA results to inform at the design phase and reduce impacts before they can be caused, improving methods towards greater sustainability considerations in composites manufacturing. 

Sowmya’s EngD project comprises:   

• Surveying existing LCA capabilities for composites to identify gaps in current tools and data 
• Developing methods of sensorising equipment for collection and homogenization of primary data for composite manufacture in collaboration with OEMs, and verifying with data from literature.  
• Design and implementation of an IoT system, to support a Universal Database Structure for LCA on composite materials   
• Build an AI framework based on a Bayesian learning model to assess confidence in LCI data 
• Collate insights from framework to create a tool for supporting design decisions, through the use of deep learning technologies, to make a system capable of automatic parametrization of structural geometries and materials  
• Design, build and evaluation of LCA-AI framework for a demonstrator structure   

Liam Marshall - Materials and design of wind turbines for preserving total product value through life – sponsored by NCC

Wind energy is a key enabler of a post-fossil fuel energy future; however, wind turbine blades themselves are large constructions of many materials, including glass and carbon fibre composites, all of which require significant sums of energy and capital to produce. Generally, they are designed for a 25-year lifespan; therefore, extending the lifespan is an attractive means of reducing through-life cost and preserving total product value, as well as reducing the number of blades that need to be replaced.  

Given the inherent difficulties in recycling composite blades, extending their operational lifespan and maintaining structural performance over time are critical to reducing the Levelised Cost of Energy (LCOE). Therefore the project focuses on both longevity and performance simultaneously improves the commercial viability and the environmental sustainability of wind energy. 

Liam’s EngD project involves:  

• Investigation of designs and materials that facilitate disassembly and support recyclability, reuse and repair. 
• Examining the targeted placement of functional materials within the composite structure to facilitate localised repair methods. 
• Employing smart digital technologies, such as a digital twin framework, to monitor cure and validate the integrity of thermal repairs.  
• Derisking these innovations for practical implantation to ensure robust, high-quality structural repairs and maximise through-life product value. 

Steven Kockaya - Ultra-efficient production lines for expanding wind capacity – sponsored by NCC

The current manufacturing approach for composite wind turbine blades uses large-scale resin infusion, but the designs of these products, and the factories that they are made in, are not configured for cost-efficient ultra-high-rate production. This puts the clean energy targets at risk, as projections show it will not be possible to produce wind turbines in the quantities required by 2030. Increasing the productivity of wind blade manufacturing would improve sustainability by reducing material and energy usage, cutting production costs, raising blade quality and accelerating volume output. Steven’s EngD project comprises:  

• Investigation of existing wind turbine design and exploring alternative designs for their energy return through changes to the manufacturing approach.   
• Consideration of new design approaches including modularity, tooling, digitalisation and automation.  
• Developing a system for reviewing concept against a range of to-be-set criteria  
• Creating new methodologies for sustainable energy and the technologies critical for enabling alternative designs  

Harvey Buhagiar - Correlating Automated Fibre Placement (AFP) Technology Manufacturing Inputs with Laminate Structural Integrity Using AI – sponsored by Magma Global 

AFP manufacturing of composites laminates is a key means to rapidly produce the large length cylindrical structures used in offshore applications. Variations in the AFP parameters influence the structural performance of composite laminates and lead to defects and scrap. Harvey’s project uses existing AI tools to analyse correlations between manufacturing data (inputs and variabilities) and laminate performance (mechanical and structural properties). Incorporating how inherent variabilities in the AFP process (such as temperature, pressure, speed and tape quality) can impact the quality and performance of the final laminate. Harvey’s EngD project investigates:   

• Using AI to detect patterns in mechanical test data and computed tomography scan data and correlate these with manufacturing parameters, laminate quality, and laminate performance  
• Building a comprehensive understanding of the relationships between process inputs, laminate quality and structural performance to support improvements in manufacturing consistency and product quality  
• Sustainability and innovation in composites engineering by minimising variability, reduce waste, and improve efficiency by understanding material behaviour, improving predictive accuracy, and reducing reliance on physical testing  
• Development of an ensemble Digital Twin model for integrating diverse physical models into a combined framework for online process control and health monitoring. 
• Leveraging Probabilistic Machine Learning techniques for Uncertainty Quantification in model predictions to enable a transparent and traceable AI pipeline.  
• Designing durable, high-performing composites while minimising environmental impact by combining manufacturing data, structural performance, and digital tools. 

Hesam Ramezani - Demonstration of maximum circularity of carbon fibres/CFRP through experiment and predictive modelling – sponsored by JLR  

Battery Electric Vehicles (BEVs) are central to the transition towards sustainable mobility. However, compared to Internal Combustion Engine (ICE) vehicles, BEVs are typically heavier, posing significant engineering challenges related to weight, efficiency, and emissions. Carbon fibre reinforced polymers (CFRPs) offer substantial lightweighting potential compared with conventional metallic materials, although their production is currently associated with high energy consumption and carbon emissions. 

To achieve future net-zero and circular manufacturing targets, it is essential to maximise material efficiency and extend the useful life of high-performance composites. Hesam’s research investigates the concept of “maximum circularity” for carbon fibre composites, challenging the conventional perception that composites have only a single service life with limited recycling potential. 

Hesam’s PhD project focuses on understanding how carbon fibre reinforcements can be repeatedly recovered, remanufactured, and reused while maintaining high mechanical performance and minimising the need for virgin raw materials. The work combines experimental research with predictive modelling to evaluate the long-term sustainability and performance of recycled carbon fibre systems for automotive applications. 

Key areas of investigation include: 

• Extending the service life of carbon fibre materials through optimised material and process selection while maintaining performance  
• Evaluating commercially available recycling technologies capable of recovering continuous, discontinuous, and milled carbon fibres  
• Developing industrially scalable upcycling routes
• Using predictive modelling to estimate the maximum achievable number of recycling and remanufacturing cycles 

Hesam's research aims to contribute towards the development of truly circular, high-performance composite materials for the next generation of sustainable vehicles. 

Vestince Mbayachi - Practical feasibility assessment of Polymer-Based Structural Composite Energy Storage – sponsored by Syensqo

Structural energy storage is a fast evolving aspect of composite materials science to enable part of the structure of a vehicle to not only provide stiffness and lightweighting, but also some of the power for its operation. The value proposition for structural energy storage requires that composite structures replace some of the function provided by energy storage devices such as batteries or capacitors; whilst retaining the ability to perform as load bearing elements of aircraft, cars or electronic devices. Vestince’s PhD project includes:  

• An electrochemical characterisation to explore and prioritise the trade-offs for a composite part containing a structural battery in terms of its ability to consistently charge and discharge  
• Investigating the tolerance of the structural composite to manufacturing processes, resistance to load, including impacts, fatigue, and to environmental conditions, such as temperature and moisture. 
• Understanding how structural composite batteries behave electrochemically when subjected to abuse tests like hole drilling and cutting. 
• Investigate the interfacial properties between the laminate and the battery component.   
• Creating multifunctional materials to provide a key development in sustainable transportation.  

With the shift from fossil fuel to renewable energy solutions, Vestince's project develops and investigates the potential use of strong, lightweight and safer structural composite batteries for electrical devices and transport applications in line with the UN Sustainable Development Goals 7 (clean energy) and 13 (climate action). 

Senagul Taskiran - Recyclable Carbon Fibre Epoxy Composites for Aerospace Applications 

The increasing use of carbon fibre epoxy composites in high-value engineering structures also makes end-of-life management a growing sustainability challenge, as these materials consume around 4-5 million tonnes of thermoset resin annually. In the context of efforts to reduce CO2 emissions, by focusing on composites made from a depolymerisable epoxy-amine-dioxazaborocane resin and post-industrial carbon fibre waste, Senagul’s PhD project will:   

• Tune the manufacturing process to maximise fibre volume fraction and minimise resin content and porosity.   
• Characterise materials in terms of the viscosity and cross-linking behaviour of the selected resin to identify the appropriate temperatures for curing cycles.   
• Assess laminate quality using state-of-the-art instrumentation, including X-ray CT and microscopy, and evaluate the mechanical performance. 
• Explore the effect of repeated manufacture-disassembly-remanufacturing cycles. 
• Creating manufacturing procedures that support recycling of composite materials into new components or secondary products, while also considering potential future application routes through essential research on manufacturing processes for circular materials. 

Senagul's project aims to develop carbon fibre-reinforced epoxy composites with the potential to be reprocessed, repaired, and recycled, thereby contributing to more circular composite manufacturing and use. 

Craig Burley - Exploiting the outstanding potential for sheet moulding compound made of repurposed discontinuous thin-ply composites 

Sheet Moulding Compound (SMC) offers low manufacturing costs, excellent formability and can be made from repurposed prepreg off-cuts. The random nature of SMCs generally leads to low strength and large variability. This limits their application in load-bearing components. There are some reports that SMC made of ultra-thin prepreg tapes (UT-SMC) can more than doubled strength can be achieved compared with conventional SMCs. To support the production of a more sustainable material, with the required material properties Craig’s PhD project investigates ultra-thin prepreg based materials by:   

• Developing reliable manufacturing, testing and modelling methods for assessing performance of repurposed UT-SMC materials and structures, targeting automotive and aerospace components   
• Repurposing out-of-shelf-life ultra-thin plies and ultra-thin prepreg off cuts from production  
• Creating new simulation and design tools that allow accurate performance assessment of the as-produced component/structure and through life durability, eliminating or reducing the need for physical testing   

Patrick Reeves Thripp - Fire performance of Fibre Reinforced Polymers (FRPs) for railway structural applications – sponsored by Network Rail

In bridge construction applications composites offer several advantages over the traditional steel and concrete materials. Their inherent corrosion resistance and lightweight properties offer significant practical benefits including: a reduction in the scale of foundations required, minimised line closure durations, and reduced long-term maintenance demands. Together, these advantages position composites as a viable and sustainable solution for the future of railway infrastructure.  

A key barrier to the wider adoption of FRPs in the railway industry is the limited knowledge of their fire performance. This gap arises from the absence of codified fire design approaches for structural elements and the constant evolution of thermoset resin formulations in the industry. Composites have a lower softening temperature compared to steel, resulting in diminished mechanical properties at temperatures of 100–120°C. Additionally, under fire conditions, FRPs can produce smoke and toxic gases, posing health risks and hindering safe evacuations on high-traffic footbridges, such as those in busy railway stations. Therefore enhancing the fire performance of composite materials is essential to realising their potential in structural railway applications, so Patrick’s PhD project investigates:  

• An economical approach to achieving composite railway structures that can meet fire performance requirements by providing a comprehensive dataset of benchmark structural fire performance for various FRP compositions commonly used in railway structures (e.g., footbridges).  
•  Strategies to enhance the fire performance, including the use of fillers, additives, fire retardant coatings and insulation barriers.  
• Fire testing on coupons and connections (bolted, adhesive, and hybrid). Bolted connections are of particular interest due to the localised heat conduction of metal components, which can accelerate failure.   
• Network Rail’s new innovative footbridge ‘FlowBridge’ and other composite infrastructure initiatives with the railway technical authorities.  

Runqiu Zhu - Microporous smart hybrid nanocomposites for enhanced cryo-compressed hydrogen storage

Hydrogen is one of the most promising alternative energy vectors that can potentially replace fossil fuels primarily to meet UK net zero target by 2050. To facilitate the move towards hydrogen economy there is an urgent need for development of efficient storage system of this ultralight gas. The type-IV cylinders currently used for hydrogen storage under extreme high-pressure are heavy, bulky, expensive. Porous materials have potential for efficient storage of hydrogen due to their ultra-high surface area and lightweight nature. However, as the compressed cylinders are required to maintain a minimum “maintenance pressure” to prevent buckling or collapsing when emptied completely, a significant amount of stored hydrogen may remain unreleased, thereby reducing practically usable hydrogen. Runqiu’s PhD project investigates: 

• The development of a class of microporous nanocomposites impregnated with magnetic nanoparticles (MNPs) to facilitate the release of adsorbed hydrogen towards end of the defueling process at the low-pressure region to maximise the amount of usable hydrogen. 
• Synthesising a range of materials and down select based on pore structure, and reported hydrogen uptake and adsorption/desorption behaviour. 
• Impregnating selected material with magnetic nanoparticles possessing suitable magnetic heating behaviour.  
• Characterising materials for physical, chemical, mechanical, and hydrogen adsorption/desorption properties. 
• Developing testing strategies to investigate magnetically assisted hydrogen release behaviour under practical operating conditions. 
• Developing a class of smart composite materials that will enhance the efficiency cryo-adsorptive hydrogen storage devices by 20-40%. 

Runqiu's project aims to facilitate the development of lightweight composite hydrogen storage materials with improved hydrogen release efficiency, potentially leading to higher usable hydrogen capacity, reduced energy consumption and overall cost, and improved durability for more sustainable energy storage solutions. 

Benjamin Stroud - De-fossilisation of Carbon Fibre – sponsored by NCC

Carbon fibre enables strategic advantages for multiple UK manufacturing sectors. For instance, increased blade length for wind turbines and high-pressure hydrogen storage systems both being enablers of a green, clean and secure future energy mix. Furthermore, they offer modular build opportunities with lower costs and reduced social burdens, while providing highly durable, high-performance, and environmentally resistant systems. However, recent innovation in the carbon fibre production process has been limited, with most using technology from the 1970s. The NCC is investing in research capability and skills to create sovereign IP that underpins UK carbon fibre production to enable innovation towards net zero, defossilised fibre. Ben’s EngD project:   

• Utilises a new carbon fibre pilot production line under development in collaboration with CPI   
• Focuses on the precursor/doping materials to produce alternative carbon fibres  
• Creates benchmarking procedures to demonstrate mechanical performance  
• Identifies new sustainable alternatives to current carbon fibre materials and manufacturing methods by developing energy efficient production processes  

Euan Mezger - Thermally induced damage in fibre-reinforced polymer composites and its effect on hydrogen permeation – sponsored by NPL and Element Materials Technology

A key element in an end-to-end hydrogen supply chain is storage that can be either as a compressed gas or as a cryogenic liquid. The pressure of compressed gaseous hydrogen needs to increase by two orders of magnitude to achieve the same energy density as liquid hydrogen at moderately low pressures. Thus, cryogenic storage of liquid hydrogen offers the possibility of reducing storage tank mass (lower pressure of liquid operation) and volume (higher hydrogen density) compared to high-pressure gas storage. A liquid hydrogen system tank is usually a thin-walled pressure vessel surrounded by a thick layer of insulation. The tank materials must be resistant to hydrogen embrittlement, impermeable to hydrogen and capable of structurally withstanding the effects of the low temperatures associated with liquid hydrogen. Also, because of the great change in temperature when the tank is filled, emptied or inspected, thermal expansion and contraction is a major concern. Euan’s EngD project aims to increase confidence in the use of FRP composites for liquid hydrogen applications by:  

• Developing experimental approaches to replicate thermally induced cracking/damage in FRP composites over typical temperature ranges experienced in operation of liquid hydrogen storage tanks (-260°C to +40°C)  
• Characterisation of laboratory-based thermally induced damage states, via destructive and non-destructive techniques, and hydrogen permeability of composites containing damage  
• Development of techniques for predicting permeation through damaged composites and devising strategies for reducing and mitigating thermally induced cracking  
• Unlocking the potential of composites to achieve environmental neutrality through the use of hydrogen as a green energy source.   

Abi Cohen - Multi-scale modelling, experimental characterisation and improvement of 3D-woven textile composites – sponsored by Rolls-Royce

3D-woven textile composites are a key technology for delivering lightweight structures with complex geometry as they offer many benefits over traditional 2D laminated composites: such as improved capacity to absorb impact energy, a higher resistance to delamination. However, despite their potential and increasing use, there is a need for fundamental research to investigate, characterise and develop models for the behaviour of these complex materials under mechanical loading. To understand damage mechanisms, it is necessary to identify the characteristics of the constituent materials and fibre architecture that are most important in determining the resulting composite properties. Abi’s PhD project focusses on optimising the mechanical performance of 3D-woven composites when they are deployed into higher temperature applications using new resin systems by investigating:   

• Combining experimental characterisation and micro- and meso-scale modelling to carry out a detailed study into the development of damage in 3D-woven textile composites  
• The damage mechanisms and identifying the key material and weave properties affecting the composite performance, e.g. the influence of weave architecture, resin pockets, resin material properties such as strain to failure, strength and fracture toughness, fibre-matrix interface properties, thermal and cure residual stresses etc.   
• Improving the materials by building upon an existing meso-scale modelling capability to provide a multi-scale modelling capability for 3D-woven textile composites.  
• Developing a set of design guidelines for reliable development and manufacturing of 3D woven composite structures. 

The project addresses Sustainable Composites Engineering by developing the modelling and characterisation tools needed to optimise 3D-woven composite performance, enabling more efficient use of materials through near net-shape preforms that reduce manufacturing waste, and supporting the development of lighter-weight composite structures in higher-temperature applications such as aero-engines, contributing to improved fuel efficiency and reduced emissions. 

Scott Haywood - Assessing the impact of environmental conditions on the ageing of wind turbine blades – Time-Temperature-Water Fatigue Crack Propagation of FRP Laminates – sponsored by EDF Renewables

Wind farms are designed to operate for over 20 years, sometimes in harsh weather conditions. However, prolonged exposure to UV, rain, humidity etc. can have an impact on the blade’s resistance to fatigue and therefore its lifetime.  Scott’s project focuses on the effect of time, temperature, and water ingress on the fatigue crack propagation in fibre reinforced polymers. The aim is to develop an accelerated fatigue testing methodology leveraging theoretical mechanics and polymer science. The test results will provide the basis for a modelling framework to better understand the progression of fatigue crack in ageing FRP materials. By improving the understanding of the factors affecting blade lifespan, operational life times can be extended with more informed repair and maintenance schedules to provide a more sustainable approach to wind energy generation. 

Scott's PhD project covers:  

• Understanding how the environmental conditions in which the blades are operating impacts their structural integrity and lifetimes.  
• Design and implementation of a controlled experimental setup for fatigue testing under varying environmental conditions.  
• Implementing image-based methods to monitor crack propagation in-situ in multidirectional representative laminates with high precision  
• Providing insight into fatigue behaviour under different temperature, strain rates, and water absorption levels using the crack accumulation information to predict long-term fatigue behaviour as function of environmental conditions.  
• Improving the durability predictions of composite structures, benefiting industries such as renewable energy, aerospace, and civil engineering. 

Guus Verkade -  Composite forming simulation – sponsored by Airbus

As the aviation industry strives to reduce its environmental impact, the development of lightweight, high performance composite materials offer a promising pathway to enhance fuel efficiency and reduce emission. Simulations of the forming processes will enable the identification of potential manufacturing issues early in the product development stage. 

Designs and production processes of composite parts can therefore be optimised leading to reduced re-work, material waste and energy consumption. The creation of simulation tools allows for a deeper understanding of the complex behaviour of composite materials during the forming process, enabling engineers to predict how these materials will perform in industrial conditions. This foresight can lead to innovations in manufacturing techniques, ensuring that components 

are not only produced more efficiently and sustainably, but also meet the stringent safety and performance standards required in aviation. Guus’ PhD project will:  

• Develop industrially applicable forming simulation methods for composite materials, ensuring scalability of the forming simulation to industrial realistic full stack laminates and large scale structural components  
• Extend  current forming simulation methodologies for composite non crimp fabric material to prepreg material 
• Characterise new materials, conduct experimental validations of the simulations and devise new testing protocols 
• Create a post processing tool to ensure correct interpretation of results. 
• Develop multiscale modelling procedures for complex components to ensure sustainable manufacturing procedures.