3D-Printed High Voltage Insulating Materials for the Green Energy Transition

The move to a green economy requires a significant expansion of the existing electricity transmission networks. There is thus an increased demand for installing new transmission and distribution assets including cables, transformers and switchgear etc. The polymer components in such equipment are typically produced by moulding and casting techniques, which are cheap when produced at very large quantities. For the power industry, however, some of the critical products are produced in comparatively smaller volumes, which result in a much higher manufacturing cost per unit especially for a new product to market. 3D Printing, one of the most effective additive manufacturing (AM) techniques, is already a proven method used in high performance industries such as formula one and aerospace and ideal for making such parts. Furthermore, 3D printing allows rapid prototyping and new approaches to be applied in fundamental research. However, there is little ageing data or knowledge on long-term operational experience using components created through this method.

In this project you will use fused deposition modelling (FDM) and direct writing to additively produce a new generation of polymeric insulators for high voltage applications. You will be using both epoxy- and silicone-based polymers with and without nanofillers, including 2D materials. You will be developing the processing-structure-property relationships with a particular focus on how the interface between the consecutively printed layers determines the electrical insulation properties. This interface is a concern since point defects are known to act as initiation sites for electrical breakdown. Technical aspects that needs exploration in this project include additive manufacturing, nanomaterial and their composites, rheology, dynamic thermal analysis, electron microscopy and high voltage testing and qualification.

The project is co-sponsored by National Grid Electricity Transmission and you will have an opportunity to work closely with an industry partner.

Eligibility

Applicants should have, or expect to achieve, at least a 2.1 honours degree or a master’s (or international equivalent) in Materials Science, Electrical Engineering, Physics, Chemistry or a related discipline.

Funding

Funding for this project covers tuition fees, UKRI minimum annual tax free stipend (currently £19,237/annum) with an additional £2,000 stipend top-up by the industry sponsor and up to a £5k/annum research training support grant for the full duration of the 4-year programme. The funding covers UK fees however, EU and international students can apply for the fee waiver from the Faculty of Science and Engineering (subject to allocation and approval). The start date is September 2025.

Before you apply

We strongly recommend that you contact the supervisors for this project before you apply. Please include details of your current level of study, academic background and any relevant experience and include a paragraph about your motivation to study this PhD project.

How to apply

Apply online through our website: https://uom.link/pgr-apply-2425

When applying, you’ll need to specify the full name of this project, the name of your supervisor, if you already having funding or if you wish to be considered for available funding through the university, details of your previous study, and names and contact details of two referees.

Your application will not be processed without all of the required documents submitted at the time of application, and we cannot accept responsibility for late or missed deadlines. Incomplete applications will not be considered.

After you have applied you will be asked to upload the following supporting documents:

• Final Transcript and certificates of all awarded university level qualifications
• Interim Transcript of any university level qualifications in progress
• CV
• Supporting statement: A one or two page statement outlining your motivation to pursue postgraduate research and why you want to undertake postgraduate research at Manchester, any relevant research or work experience, the key findings of your previous research experience, and techniques and skills you’ve developed. (This is mandatory for all applicants and the application will be put on hold without it).
• Contact details for two referees (please make sure that the contact email you provide is an official university/work email address as we may need to verify the reference)
• English Language certificate (if applicable)

If you have any questions about making an application, please contact our admissions team by emailing FSE.doctoralacademy.admissions@manchester.ac.uk.

Equality, diversity and inclusion is fundamental to the success of The University of Manchester, and is at the heart of all of our activities. We know that diversity strengthens our research community, leading to enhanced research creativity, productivity and quality, and societal and economic impact.

We actively encourage applicants from diverse career paths and backgrounds and from all sections of the community, regardless of age, disability, ethnicity, gender, gender expression, sexual orientation and transgender status.

We also support applications from those returning from a career break or other roles. We consider offering flexible study arrangements (including part-time: 50%, 60% or 80%, depending on the project/funder).

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