Manufacturing Technology & Systems Research Group

The research interests within the Manufacturing Technology & Systems group include the topics of grinding, forming, high speed machining and joining, and the processing and characterisation of polymers and polymer-matrix composites. As well as these core themes, the group undertakes research in the areas of micro-manufacturing and nanocomposites including micro-form-rolling, micro-feature characterisation of grinding tools, process monitoring in micro machining and polymer-clay nanocomposite development. Applications span automotive, aerospace, construction, biodegradable packaging and plastics recycling through to ICT and biomedical technologies. The research group undertakes research work at three levels:

• Fundamental science underpinning manufacturing processes and the formation of nanocomposites and clay reinforcement
• Application investigations in manufacturing process and polymer nanocomposite development
• Direct industry collaboration on short term projects including consulting

The group is active in the area of Environmentally Benign Manufacturing including topics such as energy efficiency in manufacturing processes, cleaner production such as minimal cooling strategies and developments in tissue scaffolds, biodegradable packaging and plastic recycling. The research group is characterised by a strong level of interdisciplinary collaboration within the Department on topics such as micro-cooling devices, micro-bio-medical devices and signal processing.

Group Leaders

• Dr. Garret O'Donnell - Assistant Professor
• Mr. Kevin Kelly - Assistant Professor
• Dr. Rocco Lupoi - Assistant Professor
• Dr. Shaun Mc Fadden - Assistant Professor
• Prof. John Monaghan - Professor Emeritus

Selected Research Projects

• High velocity mist jet cooling of machining processes: Improving the environmental impact of metal cutting
• Design and manufacture of a novel heat pipe-based hydronic heating system
• Process monitoring of micro machining operations
• An investigation of compressed air energy consumption and efficiency in automated assembly production
• Investigation the microform rolling process through experimental and FEA approaches
• Analytical modelling and experimental investigations into the use of metalic foams
• Investigating the friction stir welding process
• Investigation of the toughness of polymer-clay nanocomposites for plastics recycling
• Biopolymer-matrix composites
• An investigation into the micro-machining of biocompatible polymer materials
• Analysis of acoustic emission signals from a micro-drilling process
• The Development of a general purpose Surface Acoustic Wave (SAW) strain sensor
• Investigation of energy efficiency in polymer processing
• Development of in-process quality monitoring system for abrasive material removal processes
• Characterisation and optimisation of energy efficiency in hybrid discrete and continuous manufacturing operations
• Monitor and control during machining of polymers
• Biodegradable polymer nanocomposites
• Layer-by-layer assembly of novel bone-mimetic hybrid membranes

Research Staff and Students

Name	Position	Tel.	Email
Dr. Garret O'Donnell	Assistant Professor	+353 1 896 1184	Garret.ODonnell@tcd.ie
Mr. Kevin Kelly	Assistant Professor	+353 1 896 1465	Kevin.Kelly@tcd.ie
Dr. Rocco Lupoi	Assistant Professor	+353 1 896 1729	lupoir@tcd.ie
Dr. Shaun Mc Fadden	Assistant Professor	+353 1 896 1359	smcfadd@tcd.ie
Prof. John Monaghan	Professor Emeritus	+353 1 896 1464	jmonghan@tcd.ie
Dr. Paul Harris	Postdoctoral Research Fellow	+353 1 896 2396	harrisp@tcd.ie
Dr. Sean Nolan	Postdoctoral Research Fellow	+353 1 896 2396	snolan1@tcd.ie
Mr. Rory Stoney	Postgraduate Research Student	+353 1 896 1134	stoneyr@tcd.ie
Mr. Stuart Murphy	Postgraduate Research Student	+353 1 896 3431	murphs12@tcd.ie
Mr. Eoin O'Driscoll	Postgraduate Research Student	+353 1 896 3431	eodrisc@tcd.ie
Mr. Darren McDonnell	Postgraduate Research Student	+353 1 896 3431	mcdonnd1@tcd.ie
Mr. Barry Aldwell	Postgraduate Research Student	+353 1 896 1383	aldwellb@tcd.ie
Mr. Jeff Morgan	Postgraduate Research Student	+353 1 896 3431	morganje@tcd.ie
Mr. Niall Aughney	Postgraduate Research Student		aughneyn@tcd.ie
Mr. Ivor Humphreys	Postgraduate Research Student	+353 1 896 3038	humphria@tcd.ie
Mr. Mark Culleton	Postgraduate Research Student		culletom@tcd.ie
Mr. Conor Mc Ginn	Postgraduate Research Student		mcginncl@tcd.ie
Mr. Robin Patrick Mooney	Postgraduate Research Student		mooneyrp@tcd.ie

Equipment and Facilities

• DEFORM modelling software
• Micro-form-rolling machine
• Kistler force measurement equipment
• Vibration and Acoustic Emission sensors
• Power measurement sensors
• Micromilling machine
• Aerotech precision axes
• Westwind spindles
• High Speed Data Acquisition
• Benchtop injection moulding machine
• Charpy impact tester

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