Hybrid Multi-Laser Laser Powder Bed Fusion for Next-Generation Metallic Components

About the Project

The additive manufacturing process Laser Powder Bed Fusion (LPBF) has matured into a mainstream technology for the production of high-performance metallic components. The LPBF utilises a rapidly scanning high-power laser to scan and melt metallic powder alloys and form high-density geometrically complex end-use components. However, the LPBF melting methodology creates challenges due to limited in-situ thermal control that can generate unwanted thermal stresses in components, defects such as cracks and limited microstructural control. This PhD project offers an exciting opportunity to radically reimagine LPBF through the use of a novel hybrid multi-laser architecture.

Working with exclusive, state-of-the-art laser systems developed at the University of Sheffield, the student will explore a dual-laser LPBF system combining a traditional scanning fiber laser and a short-wavelength, high-resolution diode-based laser. This hybrid approach offers enhanced control over melt pool solidification dynamics, thermal gradients, and microstructural evolution, while simultaneously aiming to increase build speeds and reduce energy consumption.

This research aligns with industrial needs for next-generation components in sectors such as aerospace, biomedical, and energy, while also addressing the sustainability and scalability of metal additive manufacturing.

Research Themes

• Investigate multi-laser interaction mechanisms in LPBF
• Develop processing strategies for advanced metallic alloys
• Correlate process parameters with part microstructure and mechanical properties
• Assess the energy efficiency and environmental impact of hybrid LPBF
• Demonstrate scalability and productivity improvements over conventional LPBF

Training and Facilities

The successful applicant will join a vibrant and internationally recognised additive manufacturing group within the School of Mechanical, Aerospace and Civil Engineering at The University of Sheffield. The project includes:

• Access to unique hybrid LPBF equipment and state-of-the-art additive manufacturing facilities
• Training in AM process development, thermal modelling, and advanced characterisation
• Opportunities for industry engagement and conference participation

Eligibility Requirements

We welcome applications from candidates worldwide. Applicants should have:

• A minimum of a 2:1 honours degree or equivalent in Mechanical Engineering, Manufacturing, Materials Science, or a related discipline
• A strong interest in experimental research and advanced manufacturing technologies
• Desirable but not essential: experience in additive manufacturing, laser processing, or materials characterisation

If English is not your first language, you may be required to provide evidence of English language proficiency (e.g. IELTS or TOEFL), in accordance with the University of Sheffield requirements.

For more details please contact Professor Kamran Mumtaz within the School of Mechanical, Aerospace and Civil Engineering at k.mumtaz@sheffield.ac.uk

Funding Notes

This project is offered on a self-funded or externally funded basis. Applicants must demonstrate access to suitable financial support from personal, national, or institutional sources to cover tuition fees and living expenses. Unfortunately, university funding is not available for this project at this time.