Hybrid additive/subtractive manufacturing technology: design, development and validation for ceramics used in bio-implants (Ref: FP-ES-2026-1)

About the Project

This project aims to develop a hybrid multi-material manufacturing technology, consisting of an extrusion-based additive manufacturing capable of extruding ceramic pellets and thermoplastic material, and a vertical three-axis high-RPM milling machine. This hybrid machine runs two moving build platforms, making the system capable of utilising both AM and Milling units at the same time. These beds swap places to machine every layer of printing before the bed goes back to the AM station for the next layer of printing; hence making the machine capable of manufacturing highly complex, most accurate, and enclosed products, where internal structures are not accessible to the machine after full 3D printing and need to be machined while printing. The multi-material AM technology offers a solvent-dissolvable support structure, to remove after manufacturing, and before firing the final ceramic component. This machine will be verified for hydroxyapatite (HA) bone-like mineral structures used in bio-implant applications. This PhD research heavily involves mechanical mechatronics design and software development to synchronize the processes and offer manufacturing flexibility.