Alternative Production Methodologies for Formation of Complex-Geometry Graphite Components from Recovered Graphite Powder

Mersen Teesside
University of Teesside

Building on his work during his Knowledge Transfer Partnership with Mersen, Daniel will research alternative manufacturing methodologies for complex geometry graphite components, including investigating new binding materials for graphite-based additive manufacturing.

Graphite is a common material used in many industries. There is a high demand for many of its applications, including steel manufacturing, aerospace, nuclear generation and consumer electronics such as tablets and smartphones. Traditional graphite material manufacturing involves cutting items from large blocks of graphite, a wasteful method with the offcuts often rendered unusable for later operations.

Daniel’s work hopes to utilise graphite powder that is a recovered by-product of the traditional manufacturing methods. Due to the cost of raw graphite, any reduction in wastage amounts to significant financial savings, as well as a reduction in environmental impact by consuming less material. Daniel’s research potentially leads to further environmental benefits by reducing hydrocarbon emissions and reducing carbon dioxide emissions as graphite blocks are transported globally.

Daniel is a Continuous Improvement/Research & Development Engineer at Mersen, and has worked at the company since 2019. Daniel holds a Bachelor’s degree in Aerospace Engineering from Teesside University, with whom he now works on his Industrial Fellowship project. Daniel was also the leader in a national winning team in the Royal Academy of Engineering's 'Engineering a Better Future' competition. His proposal entailed designing a carbon-nanotube-impregnated geopolymer to apply to space-faring materials to protect from atomic oxygen degradation and electromagnetic radiation.

"This project will help reduce raw material requirements, through the use of recovered graphite, which in turn reduces any negative environmental impacts of our consumer products."