The Material and Composites Processing group studies how polymers and fibre composites behave during manufacturing, and uses this knowledge to design better processes. We combine numerical simulation (COMSOL, Abaqus, OpenFOAM and in-house codes) with experiments, from material characterisation in the lab to measurements on industrial production lines.
We model and analyse the processes used to make fibre-reinforced composite parts, for example pultrusion, liquid composite moulding, VARTM and roll-wrapping. Typical questions are how resin flows through and impregnates the fibre material, how heat transfer and curing develop in the part, and how residual stresses and distortions build up. The models are calibrated with our own material characterisation and validated against experimental measurements.
We work with 3D printing of polymers and fibre composites, with selective laser sintering (SLS) currently as the main focus. We have developed some of the most advanced and efficient print-scale simulation methods for SLS. They model heat transfer, sintering, crystallisation and thermal degradation, and predict density, porosity, shrinkage and discolouration of the printed parts. The models build on extensive material characterisation and are validated against measurements on printed parts.
We use AI agents to carry out complete engineering workflows, from CAD and meshing to FEA or CFD, post-processing and documentation, with workflows that allow the engineer checking and steering the work. The agents operate commercial and open-source software through MCP servers and scripting interfaces. Because the agent handles the scripting, open-source software such as OpenFOAM becomes a practical alternative to expensive commercial tools, even for complex analyses.
The group includes PhD students as well as BSc and MSc students working on their thesis projects. We work closely with industry in sectors such as consumer products, wind energy, industrial products, and building materials.
We offer BEng, BSc and MSc projects in all three areas. You are welcome to propose your own idea. We also welcome applications from students looking for an internship in the group.
Companies and institutions interested in collaborating are welcome to contact Michael Sandberg (ms@mpe.au.dk).
Funded positions are announced on the department's vacant positions page.
Full list of publications: Pure · Google Scholar
