Advanced Manufacturing of Through-Thickness Reinforced Composites

PGR-P-1884

Key facts

Type of research degree: PhD
Application deadline: Ongoing deadline
Project start date: Thursday 1 October 2026
Country eligibility: International (open to all nationalities, including the UK)
Funding: Non-funded
Supervisors: Dr Bing Zhang
Additional supervisors: Dr. Hamed Yazdani Nezhad, Professor Robert Kay
Schools: School of Mechanical Engineering
Research groups/institutes: Institute of Design, Robotics and Optimisation

<h2 class="heading hide-accessible">Summary</h2>

This PhD project aims to address one of the biggest weaknesses for fibre reinforced composites, i.e. their relatively weaker out-of-plane properties compared to in-plane properties, by developing an advanced through-thickness reinforcement (TTR) manufacturing process. The novel manufacturing process allows embedding through-thickness reinforcement in composites with minimal damage to TTR and composites themselves. This PhD project will be undertaken in the newly established Advanced Composites Manufacturing group affiliated with the world-class Institute of Design, Robotics and Manufacturing (iDRaM) at the School of Mechanical Engineering, University of Leeds. This PhD project presents a distinctive opportunity for the successful candidate to specialise in composites and manufacturing. Apart from researchers in the Institute, School and University, the PhD student will also have plenty of opportunities to intensively interacting with our industry partners in the areas of aerospace, energy, healthcare and automotive to facilitate the real-world applicability of their research findings. The PhD student is expected to publish high-quality papers on high-profile international journals, and disseminate research outcomes at national and international conferences, workshops and seminars.

<h2 class="heading hide-accessible">Full description</h2>

<h4 paraeid="{dd041517-03b9-4116-9ad6-750dd62b7068}{33}" paraid="1657558327">Project background: </h4> Fiber-reinforced composites are increasingly used across various engineering sectors as they are strong and lightweight, e.g. aerospace, automotive, renewable energy and sport. Numerous modern engineering products prominently feature composites, including A350 and Boeing 787 aircrafts, the new generation of Rolls-Royce and General Electric aero engine fan blades, and the long-span wind turbine blades manufactured by Siemens and Vestas. Additionally, composites are increasingly utilised in electric vehicles to increase power density. Fiber-reinforced composite structures are typically fabricated by layering reinforcement materials, such as carbon or glass fibres, in the thickness direction. Matrix materials, like resin, are then applied to impregnate the reinforcement, either before or after layup. Heat and pressure are applied to consolidate the entire assembly of fibres and matrix to removing voids and volatiles and achieving the desired fibre volume fractions and dimensional tolerances. However, one drawback is the lack of reinforcement in the thickness direction. Thus, composites have relatively weaker out-of-plane properties compared to in-plane properties, and they are susceptible to debonding between plies. To overcome this limitation, various through-thickness reinforcement techniques have been developed, including tufting, Z-pinning and stitching, to introduce reinforcement phase through the thickness of composites. This PhD project aim to advance the TTR technique by developing an advanced manufacturing process that allows embedding through-thickness reinforcement in composites with minimal damage to TTR and composites themselves. References Partridge, I. K. and Hallett, S. R. (2016) ‘Use of microfasteners to produce damage tolerant composite structures’, Philosophical Transactions of the Royal Society A, 374(2071). Mouritz, A. P. (2020) ‘Review of z-pinned laminates and sandwich composites’, Composites Part A: Applied Science and Manufacturing, 139(September), p. 106128. Zhang, B., Hallett, S. R. and Allegri, G. (2022) ‘Sensing delamination in composites reinforced by ferromagnetic Z-pins via electromagnetic induction’, Composites Science and Technology, 217(October 2021), p. 109113. Zhang, B. et al. (2015) ‘Micro-mechanical finite element analysis of Z-pins under mixed-mode loading’, Composites Part A: Applied Science and Manufacturing, 78, pp. 424–435. Zhang, B., Allegri, G. and Hallett, S. R. (2016) ‘An experimental investigation into multi-functional Z-pinned composite laminates’, Materials & Design, 108, pp. 679–688. Verma, K. K. et al. (2019) ‘The key role of thread and needle selection towards “through-thickness reinforcement” in tufted carbon fiber-epoxy laminates’, Composites Part B: Engineering, 174, p. 106970.

<h2 class="heading">How to apply</h2>

To apply for this project you will need to make a formal application for research degree study through the <a href="https://www.leeds.ac.uk/research-applying/doc/applying-research-degrees">University website</a>. You will need to create a login ID with a username and PIN. • For Application type please select Research Degrees – Research Postgraduate. • The admission year for this project is 2026/27 Academic Year. • You will need to select your Planned Course of Study from a drop-down menu. For this project, scroll down and select PHP Mechanical Engineering Full Time. • The project start date for this project is 1 October 2026, please use this as your Proposed Start Date of Research. • Please state clearly in the Research Information Section that the research degree you wish to be considered for is Advanced Manufacturing of Through-Thickness Reinforced Composites as well as <a href="https://eps.leeds.ac.uk/staff/14360/dr-bing-zhang">Dr Bing Zhang</a> as your proposed supervisor. Please state clearly in the Finance section, the funding that you are applying for, if you are self-funding or externally sponsored. More information on how to apply is available on our website <a href="https://www.leeds.ac.uk/research-applying/doc/applying-research-degrees">here</a>. You will be required to provide a personal statement which outlines your interest in the project you are applying for, why you have chosen it and how your skills map onto the requirements of the project. We will assess applications continuously as we receive them. We welcome and strongly encourage any potential applicants to contact the supervisor(s) for an informal discussion, prior to applying, and recommend submitting your application early. If you are applying for University or School Scholarships for 2026/27 entry, with external sponsorship or you are funding your own study, please ensure you provide your supporting documents at the point you submit your application: <ul> <li>Full Transcripts of all degree study or if in final year of study, full transcripts to date including the grading scheme</li> <li>Personal Statement outlining your interest in the project</li> <li>CV</li> </ul> If English is not your first language, you must provide evidence that you meet the University's minimum English language requirements (below). As an international research-intensive university, we welcome students from all walks of life and from across the world. We foster an inclusive environment where all can flourish and prosper, and we are proud of our strong commitment to student education. Across all Faculties we are dedicated to diversifying our community and we welcome the unique contributions that individuals can bring, and particularly encourage applications from, but not limited to Black, Asian, people who belong to a minority ethnic community, people who identify as LGBT+ and people with disabilities. Applicants will always be selected based on merit and ability.

<h2 class="heading heading--sm">Entry requirements</h2>

Applicants to research degree programmes should normally have at least a first class or an upper second class British Bachelors Honours degree (or equivalent) in an appropriate discipline. The criteria for entry for some research degrees may be higher, for example, several faculties, also require a Masters degree. Applicants are advised to check with the relevant School prior to making an application. Applicants who are uncertain about the requirements for a particular research degree are advised to contact the School or Graduate School prior to making an application.

<h2 class="heading heading--sm">English language requirements</h2>

The minimum English language entry requirement for research postgraduate research study is an IELTS of 6.0 overall with at least 5.5 in each component (reading, writing, listening and speaking) or equivalent. The test must be dated within two years of the start date of the course in order to be valid. Some schools and faculties have a higher requirement.

<h2 class="heading">Funding on offer</h2>

Self-Funded or externally sponsored students are welcome to apply. Scholarship opportunities open from October 2025 UK – The <a href="https://phd.leeds.ac.uk/funding/209-leeds-doctoral-scholarships-2024">Leeds Doctoral Scholarship</a> (closing date: 1 April 2026) and <a href="https://phd.leeds.ac.uk/funding/234-leeds-opportunity-research-scholarship-2022">Leeds Opportunity Research Scholarship</a> (closing date: 1 April 2026) are available to UK applicants. <a href="https://phd.leeds.ac.uk/funding/60-alumni-bursary">Alumni Bursary</a> is available to graduates of the University of Leeds. Non-UK – The <a href="https://phd.leeds.ac.uk/funding/48-china-scholarship-council-university-of-leeds-scholarships-2021">China Scholarship Council - University of Leeds Scholarship</a> is available to nationals of China (Now closed for October 2026 entry). The <a href="https://phd.leeds.ac.uk/funding/73-leeds-marshall-scholarship">Leeds Marshall Scholarship</a> is available to support US citizens. <a href="https://phd.leeds.ac.uk/funding/60-alumni-bursary">Alumni Bursary</a> is available to graduates of the University of Leeds. Please note that if you are successful in securing an academic offer for PhD study, this does not mean that you have been successful in securing an offer of funding. If you are applying for the Leeds Doctoral Scholarship or the Leeds Opportunity Research Scholarship, you will need to complete a separate application, specific to these scholarships, to be considered for funding. You will be responsible for paying the overtime fee in full in your writing up/overtime year (£340 in Session 2025/26), but the scholarship maintenance allowance will continue to be paid for up to 6 months in the final year of award. Eligibility Criteria <ul> <li>Applications are open to either International or Home (UK) applicants.</li> </ul> Please refer to the <a href="https://www.ukcisa.org.uk/">UKCISA</a> website or our <a href="https://www.leeds.ac.uk/undergraduate-fees/doc/fee-assessment">fee assessment page</a> for information regarding Fee Status for Non-UK Nationals. Important: Please be aware that any expenses related to the relocation of international students to the UK (<a href="https://www.leeds.ac.uk/international-visas-immigration/doc/applying-student-visa">visa, Immigration Health Surcharge</a>, flights, etc) would be their responsibility and is not covered by this award Other Conditions <ul> <li>Candidates who have previously been awarded a PhD or are currently registered on a PhD are excluded from applying. Those who were previously studying for a PhD but did not complete may be considered. </li> <li>Awards must be taken up by 1st October 2026.</li> <li>Applicants must live within a reasonable distance of the University of Leeds whilst in receipt of this scholarship.</li> </ul>

<h2 class="heading">Contact details</h2>

For further information about this project, please contact Dr Bing Zhang by email to <a href="mailto:B.Zhang2@leeds.ac.uk">B.Zhang2@leeds.ac.uk</a> For further information about your application, please contact PGR Admissions by email to <a href="mailto:phd@engineering.leeds.ac.uk">phd@engineering.leeds.ac.uk</a>

<h3 class="heading heading--sm">Linked research areas</h3>