Digital Twinning for Smart Resin Infusion and Curing in Wind Turbine Blades via Embedded Fibre Optic Sensors and Physics-Informed Machine Learning

About the Project

This PhD scholarship is offered by the EPSRC CDT in Offshore Wind Energy Sustainability and Resilience; a partnership between the Universities of Durham, Hull, Loughborough and Sheffield. The successful applicant will undertake six-month of training with the rest of the CDT cohort at the University of Hull before continuing their PhD research in Hull with co-supervision from the University of Sheffield.

Increasing productivity and yield in the manufacture of wind turbine blades is a key priority for the UK offshore wind sector, as set out in the Offshore Wind Industrial Growth Plan. The manufacturing process involves the infusion of resin into a mould to form a composite structure with glass or carbon fibre reinforcement. This is a complex thermos-chemical-flow process which is difficult to model and to monitor which has a major impact on production time and product quality.

We have developed techniques for modelling and monitoring the infusion and curing process and this PhD will bring these elements together to form a digital twin of the process. This digital twin will be used to predict manufacturing defects, such as dry spots, but also enable the development of real time control methods to adjust process parameters to maximise productivity and product quality.

Working closely with the University of Sheffield and with industry partners, you will develop and optimise the modelling techniques. This includes the development of Physics Informed Neural Networks and combine this with real-time imaging and monitoring of resin infusion in sample composite structures to build the digital twin and then explore methods for defect prediction and real time process control.

The improved process performance that this offers will have a major impact in manufacturing processes, improve the sustainability of the industry and strengthen the UK’s position as a leader in the sector.

Supervisors

1. Professor James Gilbert, University of Hull
2. Dr Hatice Sas, University of Sheffield

Training & Skills

You will benefit from a taught programme, giving you a broad understanding of the breadth and depth of current and emerging offshore wind sector needs. This begins with an intensive six-month programme at the University of Hull for the new student intake, drawing on the expertise and facilities of all four academic partners. It is supplemented by Continuing Professional Development (CPD), which is embedded throughout your 4-year research scholarship.

You will receive project-specific training in numerical modelling tools and techniques and in machine learning.

Entry Requirements

If you have received a First-class Honours degree, or a 2:1 Honours degree and a Masters, or a Distinction at Masters level with any undergraduate degree (or the international equivalents) in XX, we would like to hear from you.

If your first language is not English, or you require Tier 4 student visa to study, you will be required to provide evidence of your English language proficiency level that meets the requirements of the Aura CDT’s academic partners. This course requires academic IELTS 7.0 overall, with no less than 6.0 in each skill.

Guaranteed interview scheme

The CDT is committed to generating a diverse and inclusive training programme and is looking to attract applicants from all backgrounds. We offer a Guaranteed Interview Scheme for home fee status candidates who identify as Black or Black mixed or Asian or Asian mixed if they meet the programme entry requirements. This positive action is to support recruitment of these under-represented ethnic groups to our programme and is an opt in process. Find out more.

How to apply

Applications to the EPSRC CDT in Offshore Wind Energy Sustainability and Resilience are made to the University where the PhD project is based. You will find full instructions and links on the CDT website.

Applications for September 2026 entry will be considered on a rolling basis and applicants are therefore strongly encouraged to apply as early as possible.

Shortlisted candidates may be invited to interview as applications are received.

As offers may be made before all applications are reviewed, early application is strongly encouraged.

Funding Notes

The Offshore Wind CDT is funded by EPSRC, allowing us to provide scholarships for Home students that cover fees plus a stipend set at the UKRI nationally agreed rates, circa £20,7980 per annum at 2025/26 rates (subject to progress).