BioE Design Lab
BioE Design Lab · Research

Computational Design & Additive Manufacturing

This research integrates computational design and process modelling to investigate residual stress, distortion and fracture in additively manufactured ceramic and metal structures.

Process modelling and structural performance

My research examines how manufacturing conditions and material behaviour influence the geometry and mechanical performance of fabricated structures. Computational predictions are assessed against experimental measurements to inform design and process choices.

  • Process-induced defects: understanding residual stress, distortion and cracking.
  • Computational prediction: linking material and process models to part-scale deformation.
  • Design optimisation: using modelling and experimental validation to guide geometry and manufacturing choices.

Research projects

Funded project
ARC DECRA · DE230101683

Fellowship period: 2023–2026

Computational design of ceramic structures

The DECRA project investigates computational design approaches to defects in ceramic additive manufacturing, including residual stress, distortion and cracking. The aim is to support the manufacture of ceramic structures with improved reliability.

ARC project record ↗
Completed study · 2026

Deformation prediction in metal additive manufacturing

Collaborative work on 17–4 PH stainless steel combines multiscale modelling with a dual-cantilever calibration method. The calibrated inherent-strain model predicts part deformation and was assessed using manufactured specimens.

Related publication
Minimising residual stresses in direct metal laser sintering ↗Majji et al. · International Journal of Advanced Manufacturing Technology · 2026DOI: 10.1007/s00170-026-17890-4 ↗

Research collaboration

For collaboration on residual stress, distortion or fracture in additive manufacturing, please get in touch to discuss modelling, experimental validation or joint research.

Discuss a collaboration ↗
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