Energy Efficient Processing of Thermoplastic Composites

About the Project

Energy Efficient Processing of Thermoplastic Composites Lightweight composites are growing rapidly across industries due to a powerful combination of performance benefits, economic incentives, and environmental pressures. Among these, thermoplastic composites are experiencing particularly rapid growth because of their recyclability, which distinguishes them from traditional non-recyclable thermoset composites.

Thermoplastics can be reheated and reshaped multiple times, making them recyclable — unlike thermosets, which are permanently set after curing. This characteristic aligns perfectly with the growing global emphasis on sustainable materials and circular economy principles. As industries face increasing pressure to reduce their carbon footprints, thermoplastic composites offer a viable path to achieving these environmental goals.

In addition to sustainability, thermoplastic composites generally offer superior mechanical properties, such as high toughness and impact resistance, excellent fatigue performance, and high damage tolerance. Components made from thermoplastic composites can be welded or repaired using heat, a distinct advantage over thermosets, which cannot be reshaped or repaired once cured. This enhances both the durability and serviceability of composite structures, making them attractive for a wide range of applications. However, many high-performance thermoplastic composites require very high melting temperatures—often in the range of 250–400°C—during moulding, consolidation, or welding. This makes the processing energy-intensive, especially at large industrial scales. The equipment needed for such processing must generate (and thus withstand) high pressures and temperatures, which increases capital costs, demands more energy to run, and adds complexity to maintenance and safety protocols. In many industries, these higher energy demands currently outweigh the benefits of recyclability, particularly when production volumes are very high or when large structures are to be manufactured. To overcome these challenges, there is a critical need to use low-melt thermoplastic resins for composites that can be in-situ polymerised in an energy-efficient way. Hence, innovative processing methods must be explored and optimised to significantly reduce the carbon footprint associated with composites manufacturing. This PhD project will investigate processing of cyclic butylene terephthalate (CBT) composites in an energy-efficient way. This is a collaboration with industrial partner Metol (https://metol.co.uk/).

The successful applicant will gain hands-on experience with the fundamentals of composites manufacturing, composites characterization and processing techniques as well as with induction heating. S/he will learn to operate instruments such as differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and rheometers, as well as perform thermal and electrical conductivity measurements and mechanical testing. Important part of the project is the development of a novel methodology for processing composites by targeted heating using induction heating.

Furthermore, students will be trained in the critical analysis of experimental data, advanced material characterisation, and scientific writing skills, preparing them for impactful careers in composite materials research and industry.