Optimising Stamping Die Geometries to Eliminate Sheet Metal Scrap

About the Project

This PhD is one of a number of projects hosted by the Centre for Doctoral Training in Green Industrial Futures (CDT-GIF). We are offering pioneering research projects that will enable PhD researchers to explore key technologies and solutions that will support UK industry to reach net zero.

Project: Mitigating climate change will necessitate a significant reduction in the production of steel and aluminium, both of which contribute substantially to global emissions. A major issue is the considerable waste generated during metal processing; upwards of 30% of these materials are cut off and don't make it into final products. This waste often comes from process scrap trimmed after forming operations.

In the sheet metal forming industry, stamping scrap can easily exceed 40% for a typical automotive component. This excess material is frequently included to facilitate forming and simplify die design. Historically, waste reduction hasn't been a primary focus for die designers, as material costs were relatively low compared to factors like labor and production rates.

Recent research, however, has demonstrated that targeted interventions in die designs can significantly increase material utilization without requiring replacement of existing process infrastructure. The "folding-shearing" process [1], for instance, was introduced to eliminate the need for blank holders in stamping operations and is now being commercialized by DeepForm Ltd, an industrial partner for this project.

The design of stamping dies is a highly technical process, relying primarily on sophisticated simulations and human expertise. It can be time-consuming, and there's often no guarantee of achieving an optimal design. Current software predominantly focuses on optimising for formability and feasibility, often adhering to conventional die designs.

This project will adopt cutting-edge data-based optimisation approaches to design die geometries that minimize the size of the blank needed to produce a specific part. The scale of this problem necessitates combining dimensional reduction with fast optimisation methods to ensure computational tractability.

Industrial Partner

DeepForm, a Cambridge-based startup, engages with automotive OEMs and first-tier suppliers. They leverage their patented fold-shear metal pressing processes to reduce costs and CO2 emissions. Originating in academia, DeepForm continues to support research through various avenues. This project will greatly benefit from their extensive knowledge base, internal expertise, and growing exposure to the stamping industry.

Supervisors: Dr Evros Loukaides

CDT in Green Industrial Futures: The CDT is funded by the UK Engineering and Physical Sciences Research Council and is a partnership between Heriot Watt University, Imperial College London, and the Universities of Sheffield and Bath. The CDT is further supported by contributions from industrial partners. Bringing these leading universities together allows CDT-GIF students access to a wide range of academic expertise, resources and facilities.

The CDT-GIF has an exciting and challenging programme specifically designed for top performing junior researchers. Alongside the four-year research project, students will receive expert training and opportunities to contextualise their research within the wider net zero landscape, including:

• Residential taught courses at each of the partner universities in Years 1 and 2 that provide training in the systematic considerations for industry including: Life Cycle Analysis (LCA), technoeconomics, business models, policy & regulation, public engagement, plant operation.
• An international opportunity in Year 2 or 3 of the programme, including opportunities to visit a world-leading facility, conference or forum and explore the global context of industrial decarbonisation.
• A work placement with one of our industrial partners.
• A bespoke ‘net-zero leadership programme’, including regular exchanges with cohort members from the other universities, student-led activities, industry challenge sandpit, industrial site visits, and professional development opportunities.

Candidate requirements: As a minimum we require candidates to have a First-class or 2:1 Meng, MSc, or MA with merit (over 60%) in a relevant area i.e. Applied Mathematics, Physics or a related Engineering discipline. Applicants who have a First-class BSc/BEng (Hons) and can demonstrate significant relevant industry/research experience may also be considered.

Non-native English speakers must ensure they meet the English language requirements.

Enquiries and Applications

For informal enquiries about this project contact Sophia Coe sc3716@bath.ac.uk or cdtgreenindustrialfutures@hw.ac.uk

Apply via: https://greenindustrialfutures.site.hw.ac.uk/the-programme/how-to-apply/

When applying, you will have two options:

• Apply to up to two specific projects, or
• Apply to the CDT-GIF programme, indicating up to two universities where you would like to study.

Selecting the Correct Project

Applications are processed using the project number. Please ensure you select the correct one:

• Project Title: Optimising Stamping Die Geometries to Eliminate Sheet Metal Waste
• Project Number: BU-3-4

Applications cannot be submitted without a project number. Enter the project title as well to help us verify your selection. Incorrect details may cause delays in processing.

Equality, Diversity and Inclusion. We warmly encourage applications from individuals of all backgrounds, experiences, and perspectives. Our programme values diversity as a cornerstone of innovation and collaboration, and we are committed to creating an inclusive environment where everyone feels respected, supported, and empowered to thrive. The CDT-GIF are committed to ensuring flexibility throughout our programme to support student’s needs and personal circumstances, for example those with medical conditions, caring responsibilities and other considerations. For example, we are open to exploring part-time options if appropriate for the nature of the research.

Keywords: Metal forming; Sustainable manufacturing; Advanced manufacturing

Funding Notes

The programme is four years and starts in September 2026. Funding includes full UK fees, tax-free stipend (2025/2026 stipend is £20,780), plus budget for travel and consumables. Currently open to all students, home and international.

References

[1] Cleaver et al (2022), Producing isolated shrink corners by folding-shearing, CIRP Annals