Multi-objective optimisation of AM parameters for recycled nylon C15 carbon composites for UAVs
This research explores sustainable additive manufacturing using recycled Nylon C15 carbon fibre composites, focusing on optimising 3D printing parameters to enhance mechanical performance. The project targets lightweight, high-strength applications, particularly in UAV structures, supporting circular economy principles and advanced engineering design.
Research Opportunities
Summary
This research project focuses on the development and optimisation of sustainable additive manufacturing processes using recycled Nylon C15 Carbon fibre-reinforced polymers for high-performance engineering applications. With increasing global emphasis on circular economy principles and material sustainability, the reuse of high-value polymer composites in 3D printing presents a promising pathway to reduce environmental impact while maintaining structural performance.
Aims
The primary aim of this study is to optimise fused filament fabrication (FFF) process parameters for recycled Nylon C15 Carbon composites to enhance mechanical properties, structural integrity, and print quality. Particular emphasis will be placed on lightweight structural applications, including components for unmanned aerial vehicles (UAVs) such as drone frames, arms, and functional mounts.
Methods
The research will adopt a design of experiments (DoE) approach using the Taguchi method to systematically investigate the influence of key process parameters, such as nozzle temperature, layer height, print speed, and infill density. A suitable orthogonal array (e.g. L9 or L16) will be employed to identify optimal parameter combinations with reduced experimental effort. The outcomes will be analysed using signal-to-noise (S/N) ratios and analysis of variance (ANOVA) to determine the significance and contribution of each factor.
Mechanical performance will be evaluated through standardised testing, including tensile, flexural, and impact tests, alongside microstructural analysis to assess interlayer bonding and porosity. The optimised material and process parameters will then be applied to the fabrication of representative UAV components, enabling validation under realistic loading conditions. The study is expected to establish clear process–structure–property relationships for recycled composite filaments in additive manufacturing.
Outcomes
This project offers significant contributions to both academia and industry by advancing knowledge in sustainable composites, additive manufacturing optimisation, and lightweight design. The outcomes are particularly relevant to sectors such as aerospace, automotive, and energy systems, where demand for high-performance, low-weight, and environmentally responsible materials is rapidly growing.
Candidate
The ideal candidate should have a background in Mechanical Engineering, Materials Science, or a related discipline, with knowledge of additive manufacturing and/or composite materials. Experience in experimental design, mechanical testing, or numerical analysis (e.g. CAD/FEA tools) would be advantageous. Strong analytical, problem-solving, and communication skills are essential.
Supervisors
Principal Supervisor: Dr Shahneel Saharudin
Co-Supervisor: Dr Muhammad Younas
Research Theme
Find other Research Degrees in the same theme:
About our Research Degrees
We welcome specific ideas from applicants for a potential research degree topic. The University offers a number of potential self-funded topics in each School which you could consider developing your research project around.
It is not unusual for a proposed research degree topic to evolve as you progress through the application stage and even your future studies. This ensures the best match of your academic/professional experience with that of your supervisory team.
Occasionally, the University will also advertise available funded studentships, for very specific topics or subjects:
If you need any further support prior to applying, please email researchdegrees@rgu.ac.uk
Entry requirements
Entry Requirements for Research Degrees
Normal entry requirements are a first or upper second class honours degree from a University of the United Kingdom, or from an overseas University, or degree equivalent qualification, subject to the approval of Robert Gordon University.
Applicants holding other qualifications shall be considered on their merits and in relation to the nature and scope of the proposed research programme.
Applicants will normally register for an MSc/PhD or MRes/PhD with transfer to PhD dependent on satisfactory progress. However, applicants who already possess a Master’s degree which includes a significant research component could be registered directly for a PhD, subject to a satisfactory research proposal, and clear evidence of research expertise.
Some Research Degree Topics require employment experience, research experience and/or transcripts for international qualifications.
Contact researchdegrees@rgu.ac.uk to see if you are eligible.
English Language
Any applicant whose first language or language of previous University-level instruction is not English must normally demonstrate competence in English. This should be a score of IELTS 6.5 with 6.5 in all elements, or an approved equivalent.
We accept a variety of in-country and secure English language tests, find out more:
Please note, some courses may require a higher standard of English than stated in this page. Contact researchdegrees@rgu.ac.uk for further information.
Fees & Costs
For Academic Year 2025/2026
School of Health, School of Computing, Engineering and Technology and School of Pharmacy, Applied Sciences and Public Health.
UK Students
- Full time - £5,006 per academic year
- Part time MPhil/PhD - £3,000 per academic year
- Part time MRes/MSc by research - £3,000 per academic year
International Students
- Full time - £20,030 per academic year
- Part time MPhil/PhD - £12,020 per academic year
- Part time MRes/MSc by research - £12,020 per academic year
For Academic Year 2024/2025
UK/EU Students
- Full time - £4,786 per academic year
- Part time MPhil/PhD - £2,870 per academic year
- Part time MRes/MSc by research - £2,390 per academic year
International Students
- Full time - £16,980 per academic year
- Part time MPhil/PhD - £10,190 per academic year
- Part time MRes/MSc by research - £8,490 per academic year
Additional Costs
Some other costs are not included in the course fees:
- The cost of books that you may wish to purchase.
- Costs associated with any placement / study abroad
- Accommodation and Living Costs
- Printing
Alumni Discount
Robert Gordon University is delighted to offer a 20% discount on course fees for all alumni who have graduated from RGU.
Scholarships and Financial Awards
Postgraduate research students will normally make their own arrangements for payment of fees. However you may qualify for a scholarship or financial award:
Funded Studentships
Occasionally, the University will also advertise available funded studentships, for very specific topics or subjects:
Disclaimer
For new intakes, course fees are reviewed and published annually for each mode of delivery. Tuition fees are fixed for the duration of a course at the rate confirmed in the offer letter. For further information:
How to Apply
Applications
All applications should be made via the University's online application for research students.
Before you apply, find out more about the application process, research proposal writing guides, routes and durations:
Our Research degrees usually start in February and October each year. There are no formal deadlines for you to submit your application, though we recommend you submit it as early as possible in order to ensure we can help you join us at your preferred time.
Completed application forms should be accompanied by:
- Degree certificate
- Statement of purpose, detailing why you would like to study this degree in the UK, and why you have chosen RGU.
- A short research proposal, in the range of 1,500 - 3,000 words, containing a rationale and background, study aims and objectives, a literature review, proposed research methods and a full reference list.
Further guidance on the application process:
English Language Requirements
All applicants whose first language is not from a recognised English speaking country will be asked to provide evidence of their English language skills as part of their offer to study at RGU.
Find out more about the English language qualification we accept:
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