The Development of New Piezoelectric Sensors for Force Measurement Applications

About the Project

Subtractive manufacturing processes such as turning, milling, and drilling remain the backbone of industrial production across sectors, including aerospace, automotive, and energy. Despite the rise of additive technologies, subtractive methods continue to dominate due to their precision and reliability. However, these processes are not without challenges. Excessive heat generation, rapid tool wear, and sudden tool fractures are common issues that can lead to costly downtime, compromised product quality, and even damage to critical components that are difficult or impossible to repair. These problems are particularly acute in high-value manufacturing environments, where precision and reliability are non-negotiable.

One of the most effective ways to mitigate these risks is through real-time monitoring of cutting forces. Accurate force measurement allows manufacturers to detect early signs of tool degradation or process instability, enabling timely intervention before damage occurs. However, existing force measurement systems are often prohibitively expensive and lack the flexibility needed for diverse machining operations. Many systems are designed for specific tools or setups, requiring manufacturers to invest in multiple devices to cover different processes. A solution that is neither scalable nor economically viable, especially for small and medium-sized enterprises (SMEs). In fact, recent industry surveys suggest that over 60% of SMEs cite high equipment costs and lack of adaptability as major barriers to adopting advanced monitoring technologies.

This PhD project seeks to address these limitations by developing a new generation of piezoelectric sensors that are both cost-effective and versatile. Piezoelectric materials, such as polyvinylidene fluoride (PVDF), offer a promising foundation for sensor development due to their flexibility, sensitivity, and ease of integration into various manufacturing environments. The project will explore the design and fabrication of sensors capable of accurately measuring cutting forces across a range of machining operations, with the goal of creating a universal sensing solution that can be deployed widely in industry. The research will involve a deep investigation into several key areas. These include identifying the most suitable piezoelectric materials for sensor construction, determining optimal sensor geometries, such as whether nanofibers or solid layers offer superior performance, and evaluating manufacturing techniques like electrospinning, solution blow spinning or inkjet printing for scalability and cost-efficiency. Each of these questions represents a significant research challenge, and their resolution will contribute to the development of a sensor system that is not only technically robust but also commercially viable.

This project is ideally suited to candidates with a background in mechanical engineering, materials science, electronics, or applied physics. It offers the opportunity to work at the intersection of advanced manufacturing and sensor technology, contributing to a field that is increasingly vital to the future of smart manufacturing. The global piezoelectric sensor market is projected to reach $4.87 billion by 2035 [1], driven by the growing demand for intelligent monitoring systems and Industry 4.0 solutions. By developing new sensor technologies, this research will help position manufacturers to meet these demands while improving efficiency, reducing waste, and enhancing product quality.

The successful candidate will be part of a dynamic research environment and will have opportunities to collaborate with industrial partners, ensuring that the outcomes of the project are grounded in real-world needs and applications. This is a chance to contribute to a transformative area of research with direct implications for the future of manufacturing.

Academic qualifications

First degree (minimum 2:1 classification) in Mechanical, Manufacturing, Textile, Materials, or possibly Electrical Engineering

English language requirement

IELTS score must be at least 6.5 (with not less than 6.0 in each of the four components). Other, equivalent qualifications will be accepted. Full details of the University’s policy are available online.

Essential attributes:

• Good fundamental knowledge of materials and manufacturing
• Independence and initiative
• Time Management and organisation
• Communication skills
• Integrity and ethics

Desirable attributes:

• Teamwork
• Passion for the subject

APPLICATION CHECKLIST

• Completed application form
• CV
• 2 academic references, using the Postgraduate Educational Reference Form (download)
• Research project outline of 2 pages (list of references excluded). The outline may provide details about
  1. Background and motivation of the project. The motivation, explaining the importance of the project, should be supported also by relevant literature. You can also discuss the applications you expect for the project results.
  2. Research questions or objectives.
  3. Methodology: types of data to be used, approach to data collection, and data analysis methods.
  4. List of references.
• The outline must be created solely by the applicant. Supervisors can only offer general discussions about the project idea without providing any additional support.
• Statement no longer than 1 page describing your motivations and fit with the project.
• Evidence of proficiency in English (if appropriate)

To be considered, the application must use

• the advertised title as project title

For informal enquiries about this PhD project, please contact i.shyha@napier.ac.uk

PhD Start Date: October 2026

Application link: https://evision.napier.ac.uk/si/sits.urd/run/siw_sso.go?mP9MDnTs1Rwm8ftb3WVhDhXtraMQwXSUMdHC9wIc34es5bJqXf

Funding Notes

International applicants should note that visa application costs and the NHS health surcharge are additional costs to be taken into consideration, and successful applicants will need to cover these expenses themselves.