I'm the technical director of Meshworks, an OxMet business division focused on the commercialisation of additive technologies for medical orthopaedic devices. At OxMet Technologies, I am leading the simulations, process modelling, and metamaterials design acticities. Prior co-founding OxMet I held a Senior Research Fellowship at the University of Oxford, where I also completed my doctoral studies in the field of engineering science. You may find more information in my LinkedIn profile.
Following you may find more details regarding my work experience and education with a short paragraph in each describing my responsabilities and outcomes.
January 2019 - Present
Meshworks offers a new design and manufacturing platform for orthopaedic custom implants through the use of additive manufacturing. I am responsible for the development of the key technologies and services that enable our integrated medical solutions platform.
July 2017 - Present
I am part of the founding team of OxMet Technologies, a spin-out company from the University of Oxford which specialises in computational design of high-performance alloys and next-gen manufacturing processes. One of my technical roles in the start-up is to couple alloy design, process simulation, and metamaterial structure optimisation to enable the next generation of additive manufacturing components.
October 2017 - June 2018
As a Senior Research Fellow, I was responsible to lead, manage and deliver high value research programmes at Oxford, within a growing collaborative effort with the Ishikawajima Heavy Industry (IHI) company of Japan with aim of establishing a Oxford-IHI Centre for High-Temperature Materials. Technical responsibilities included the experimentation and the numerical modelling of processing and behaviour of polycrystalline superalloys for gas turbine engines.
January 2016 - September 2017
Documented technical summaries of investigation results for our industrial customers; provided best advice based on data analysis and experimental data interpretation. Characterised, analysed and modelled the mechanical performance of novel materials under extreme conditions: i.e. high-temperatures and/or high strain rates. Developed advanced modelling techniques using finite element methods, crystal plasticity, and cohesive zone modelling for the fracture analysis of micromechanical behaviour; coupled with stress analysis of manufacturing processes and in-service conditions.
October 2011 - October 2015
Rolls-Royce plc sponsored research work. Acted as lead technical presenter at multiple project review meetings; liaised with stakeholders; reported periodic progress in a weekly or monthly basis to the Process Modelling Group in Rolls-Royce Derby and the Manufacturing Technology Team in Barnoldswick. Developed methods have improved the fan blade production efficiency; advised Rolls-Royce in their exploitation to accelerate the introduction of new process developments.
May 2014 - May 2017
Responsible for co-ordinating a series of laboratory-scale experiments to introduce critical aspects of the mechanical performance of solids to third-year undergraduate engineering students.
December 2012 - January 2016
D.Phil. in Engineering Science (St. Anne's College) Modelled and optimised using finite element methods a series of manufacturing processes crucial for the aerospace industry – i.e. superplastic fan blade forming. Experimental analysis and numerical modelling for material behaviour based on the high-temperature micromechanics of titanium and its alloys.
October 2010 - June 2011
Masters degree in Aerospace Engineering with specialization on aircraft structures and space vehicles.
October 2009 - October 2010
Awarded a 1-year Erasmus Scholarship at the University of Rome 'La Sapienza'
October 2005 - October 2009
Bachelor degree in Aeronautical Engineering.
I have developed finite element models to simulate a wide variety of engineering challenges. A few examples include: superplastic forming, turbine disc stress assessment, ring-rolling, and metal forming. The models that I developed enabled: (i) the evaluation of conceptual blade designs, (ii) an ability to manufacture ‘right-first-time’, (iii) the elimination of trial and error experimentation, and (iv) a better understanding of the underlying physics of the process. Much of this work has been highly relevant to the needs of the aerospace industry.
Accurate finite element models need validated material laws which capture the relevant phenomena. This is, material models that are able to predict the stress-state of solids during the evolutionary nature of deformation. I have formulated, calibrated, and validated physically-based internal state variable models (ISVs) to simulate the macroscopic behaviour of materials using a number of dynamic equations that represent the underlying evolutionary nature of the physical phenomena.
I have developed new experimental techniques to pinpoint and quantify the high-temperature regime of materials. One aim has been to propose computational models and to select optimal processing conditions for manufacturing. I have put special emphasis on accelerating the quantification of mechanical characteristics, greatly improving the speed and efficiency at which critical engineering design data can be acquired. The goal is to combine high-throughput experimentation and modelling for the fastest deployment of engineering products.
I have analysed ans characterised the behaviour of materials under impact. Impact events can have catastrophic consequences - think of bird strike in jet engines. Having a good understanding of the high-rate behaviour of materials is critical in making the right engineering decisions.
The mechanisms of high-temperature deformation in metals are controversial – particularly at the scale of crystals. My work has provided insights which have confirmed the microstructural mechanisms of several metallic systems when deformed at extreme temperatures; I have used this approach to study metal-forming processes, but also the creep and fracture regime in the Ni-based superalloys used for jet propulsion and power generation.
I have developed an experimental setup that allows surgeons to simulate the loads that an implanted femur suffers during a fall. This study measured the periprosthetic fracture torque of two different brands of hip stems implanted in synthetic femurs. The results highlight the stark difference in mechanical response between two of the most popular cemented hip stems currently in use.
In order to rationalise the effect of hip design on periprosthetic fracture, finite element models were developed. These models consider the different mechanical and fracture properties of each of the components that are found in a cemented hip stem and are able to replicate the fracture process virtually. The models explain the effect of implant geometry on periprosthetic fracture and can be used to improve the design of hip implants.
Miniaturised tensile tests coupled with in-situ scanning electron microscopy are used to deduce the mechanics of fracture. This allows the damage initiation, evolution and failure processes to be observed directly. The method that I developed allow quantitative estimation of strength and toughness in grain boundaries. This information is very useful in the design of more resistant materials.
I have developed advanced crystal plasticity and cohesive zone models that can simulate representative volume elements of polycrystalline structures. The simulations are able to predict fracture at the grain boundaries. I have validated the models with experiments in polycrystalline materials.
Traditionally, new alloys have been designed through empiricism - their chemical compositions have been isolated using time consuming and expensive experimental campaigns. Due to the large number of chemical combinations, is unlikely that alloys entirely optimised . Alternatively, I have employed the CALPHAD method (CALculate PHAse Diagram) to calculate the phase diagram and thermodynamic properties for a large series of alloy compositions. Then, I have used this information to make estimates of the relevant thermo-mechanical properties across a very broad compositional space. As an example, the image below shows the alloy design process to improve the formability of titanium alloys at low temperatures.
I have used additive manufacturing to produce open-cell scaffolds with tailored design to match bone performance. This will allow more efficient implants with lower revision rates. We employed triply periodic minimal surfaces within a range of sizes and volume fractions designed to suit the needs of the different existing bone tissues. Compression experiments reveal the stiffness and the collapse load of the scaffold as a function of geometry and density. This work confirms the suitability of the designed lattices to match the stiffness and the strength over a wide range of bone types.
I have developed a parametric design framework that is able to generate large porous structures with architectures that mimic the natural shape of trabecular bone. The framework is scalable and flexible, and can be employed to generate large controllable structures inside medical devices for the most optimal osseo-integration.
The following summarises my fields of expertise and areas of professional interest.
Specialisation in the application of high level finite element analysis (FEA) for both static and dynamic calculations to carry out advanced engineering analysis, manufacturing optimisation, and failure studies. Expertise using advanced computational tools to optimise the engineering design of components. Coupled with a deep understanding of materials science, this allows me develop ideas which are reliable, feasible, and that perform beyond tolerances.
Experience as a programme director at a technology start-up. Skill managing people and projects in a fast-paced and constantly-changing environment. Ability to manage and prioritise multiple customer and internal development projects with a wide variety of budgets, timelines, and scopes. Experience co-supervising university students and ability to define long-term research and development programs with both high scientific and commercial value.
Experience with design for additive manufacturing. A fundamental understanding of the metallurgical principles of the process allows me to propose designs which take into consideration the limitations of AM, but also designs that exploit the unique design capabilities that the process enables. Expertise in this area include: advanced light-weighting, topology optimisation, design functionalisation, and latticing.
Experience in developing mathematical models that capture the underlying behaviour of materials. Expertise in codifying and implementing these models into finite element software packages. Moreover, knowledge of batch processing and experience in using analysis tools to read and process large sets of data.
Deep understanding of materials and their underlying science. In particular, expertise in metallic alloys for high-performance engineering applications. For example, high-temperature superalloys, high-stregth Ti alloys, and biomedical materials. This understanding extends across a wide length-scale: from their atoms, across their microstructure, up to their relationship to critical thermo-mechanical properties.
Experience creating a high technology business from scratch. Good understanding of every step involved in going from the conception of a business idea to the formalisation and the funding of the enterprise. Deep involvement in the development of ideas and technology into long-term value projects.
34 Centre for Innovation and Enterprise
Begbroke Science Park
Begbroke, OX5 1PF
Office: (+44)1865 309 632