About the Project

Double diaphragm forming (DDF) is a promising means of producing sustainable fibre-reinforced composites, offering key advantages over traditional autoclave processing of prepreg sheet materials. The benefits, including reduced manual labour and shorter process times, align with the broader goals of environmentally responsible manufacturing, material efficiency, and high-performance composite production. Despite these benefits DDF for larger volume manufacturing achieving defect-free components remains a challenge, as numerous interdependent material and process parameters are involved that are difficult to optimise manually. Maintaining precise fibre orientation to prevent localised wrinkling, requires careful control, otherwise DDF components are prone to defects, which may exhibit inferior mechanical properties compared to those produced using traditional processes. Further challenges exist in understanding the temperature sensitivity and differing cure cycles of the component sheet materials as well a dealing with their directional properties because of the anisotropic nature of the prepreg sheets. Achieving the desired geometry in a defect free DDF finished component requires careful selection of materials and processing parameters. The EngD student will:

• Develop a reliable simulation model to identify suitable material combinations to substantially reduce, or even eliminate, the need for physical feasibility trials.
• Define a suite of deployable tools and predictive models to identify optimal polymer film and prepreg chemistry combinations over a range of cure cycles.
• Provide you with hands-on experience at one of the world’s leading specialty chemicals companies, working with real-world industrial-scale composite manufacture, alongside state-of-the-art composite materials.
• Deepen your passion for automated manufacturing processes, driving the development of sustainable composite structures for high-performance applications, preparing you for a career at the intersection of innovation and industry.
• Support Syensqo’s ambition of promoting DDF in the composites industry by developing the knowledge, skills and end-user tools.