This project offers an opportunity to develop an automated geometric characterisation framework for wire-based directed energy deposition additive manufacturing (w-DEDAM). You, as a MSc by Research student, will work at the intersection of 3D scanning, point cloud processing, and industrial metrology to quantify as-built geometry, a task traditionally reliant on manual measurement and expert interpretation. By integrating multi-view acquisition, automated registration, and data-driven surface analysis, the research aims to separate localised deposition error from thermal distortion and enable in-process geometric monitoring. This is ideal for candidates interested in digital manufacturing, computer vision, and solving complex, real-world engineering challenges.
Wire-arc Directed Energy Deposition (wire-arc DED-AM, also termed WAAM) is a near-net-shape metal additive manufacturing process capable of producing large-scale components at high deposition rates, with growing adoption across the aerospace, energy, and defence sectors. A persistent barrier to its industrial qualification is dimensional and geometric assurance: the as-built geometry deviates from the nominal design as a result of both localised deposition variability and cumulative, residual-stress-induced distortion. Reliable characterisation of build geometry is therefore central to process qualification, and increasingly to the development of closed-loop process control.
The project aims to develop and validate a methodology for the automated geometric characterisation of WAAM-deposited walls from point cloud data, and to establish data-analysis techniques capable of discriminating process-induced geometric error from residual-stress-induced distortion.
The student will be based at the Welding and Additive Manufacturing Centre (WAMC), a renowned hub for impactful research into advanced fusion-based processing and manufacturing methods. The Centre's contributions to industry are demonstrated through its extensive MSc and PhD research initiatives and its ongoing technology development programs in large-scale additive manufacturing. The student will become part of a diverse and dynamic research community at WAMC, fostering collaboration and innovation. Additionally, there will be opportunities to work with WAMC’s industrial partners.
The project will deliver a validated methodology and software pipeline for the automated geometric characterisation of w-DEDAM structures, capable of merging multi-view scans into a single dimensionally consistent representation without manual intervention. It will establish quantitative descriptors that distinguish process-induced deposition error from residual-stress-induced distortion, allowing as-built geometry to be interpreted correctly rather than attributed to a single cause. Demonstrating inter-layer measurement under process conditions will provide the geometric feedback needed for future closed-loop control. The outcomes will support industrial qualification of large-scale metal additive manufacturing and are expected to generate peer-reviewed publications and tools transferable to the Centre's industrial partners.
The student is expected to acquire the following (including but not limited to) knowledge and skills from the research in this project:
- 3D metrology and optical scanning: hands-on experience designing acquisition strategies and operating structured-light or laser scanning equipment on real industrial hardware.
- Point cloud and geometric data processing: registration, coordinate transformation, surface reconstruction and feature extraction.
- Software engineering for research: building an automated, reusable pipeline rather than one-off scripts, with version control and documentation that others can pick up.
- Experimental design and data interpretation: planning deposition trials, isolating confounded effects, and defending conclusions drawn from noisy measurement data.
- Applied additive manufacturing knowledge: practical understanding of a production-scale metal AM process and the qualification requirements that govern its industrial adoption.
- Industrial engagement: working alongside a research centre's industry partners, and translating research output into something an engineering team can actually use.
- Technical communication: peer-reviewed publication, conference presentation, and reporting to non-specialist and industrial audiences.
- Independent project management: scoping, prioritising and delivering a multi-stage research programme to deadline.
At a glance
- Application deadline23 Jun 2027
- Award type(s)MSc by Research
- Start date27 Sep 2027
- Duration of award1 year (full-time)
- EligibilityUK, Rest of world
- Reference numberCRAN-0109
Entry requirements
Applicants should hold the equivalent of a first or second-class UK honours degree in a related discipline, such as mechanical, manufacturing, or general engineering. International candidates must also meet the English language requirements set by Cranfield University. The successful candidate should demonstrate self-motivation, proactivity, and good communication and teamwork skills.
Funding
A self-funded MSc by Research.
Diversity and Inclusion at Cranfield
At Cranfield, we value our diverse staff and student community and maintain a culture where everyone can work and study together harmoniously with dignity and respect. This is reflected in our University values of ambition, impact, respect and community. We welcome students and staff from all backgrounds from over 100 countries and support our staff and students to realise their full potential, from academic achievement to mental and physical wellbeing.
We are committed to progressing the diversity and inclusion agenda, for example; gender diversity in Science, Technology, Engineering and Mathematics (STEM) through our Athena SWAN Bronze award and action plan, we are members of the Women’s Engineering Society (WES) and Working Families, and sponsors of International Women in Engineering Day. We are also Disability Confident Level 1 Employers and members of the Business Disability Forum.
Our Student Wellbeing and Disability support team provide a range of support and coordinate reasonable adjustments for students with disabilities, specific learning differences and mental and physical health conditions. Please contact studentsupport@cranfield.ac.uk for support queries, the information you provide will be confidential.
Cranfield Doctoral Network
Research students at Cranfield benefit from being part of a dynamic, focused and professional study environment and all become valued members of the Cranfield Doctoral Network. This Network brings together both research students and staff, providing a platform for our researchers to share ideas, identify opportunities for collaboration and create smaller communities of practice. It aims to encourage an effective and vibrant research culture, founded upon the diversity of activities and knowledge.
Doctoral Researchers’ Core Development (DRCD) Programme
An important part of the research journey is developing key skills that will benefit a research students research and professional development. As a research student at Cranfield, you will be expected to attend the DRCD programme which comprises of four 1 week units which cover the key stages of your research journey. Workshops are held face to face, providing the opportunity for you to network and collaborate with your peers during these valuable development sessions. For further details visit Cranfield's Doctoral Network.
How to apply
For further information please contact:
Name: Dr Jian Qin
Email: J.Qin@cranfield.ac.uk
Phone: +44 (0)1234 758214
This vacancy may be filled before the closing date so early application is strongly encouraged.
Note, your application will not be considered unless all relevant documents have been uploaded. For more information please visit Applying for a research degree.
