Hybrid laser-electrochemical (micro)machining of advanced materials

To be successful you should :

• Be a motivated candidate with a Masters degree in Mechanical Engineering, Materials Engineering, Production Engineering or a related field in Science and Engineering.
• Have strong interest in manufacturing with prior research or industrial experience.
• Have experience with experimental machines, practical knowledge of design of experiments, data analysis and presentation, and basic metallography and metrology techniques.
• Have knowledge of electrochemical manufacturing and electrochemistry analysis techniques (preferred but not mandatory).
• Have a critical mindset and able to formulate research questions.
• Have good social and communication skills to work in a team.
• Have good knowledge of English is necessary.

As manufacturing increasingly prioritizes performance and functionality, hybrid manufacturing approaches—integrating two or more types of process energies—have emerged. These methods address the challenges of working with novel materials while ensuring the preservation of surface characteristics and designed performance. Hybrid laser-electrochemical micromachining (LECM) is one such technique which involves synergistic and coaxial application of green laser and electrochemical micromachining processes with an aim to machine advanced difficult-to-cut materials with high precision and surface quality, while preserving material properties. The LECM technology has been developed in-house at the MPE group and research is on-going on its machining capabilities and fundamental removal mechanisms. Therefore, this research will explore machining of advanced materials through LECM for studying the machining performance through process-material interactions while advancing on-machine capabilities through digital frameworks. The project will generate new knowledge to scale-up the LECM technology and advance the fields of hybrid manufacturing and machining of advanced materials.

The project will have a sound mix of applied and fundamental research elements including hardware development, hands-on experiments, process simulation, in-process signal analysis, metallography and metrology, providing the PhD researcher the opportunity to develop multidisciplinary expertise. Relevant state-of-the-art infrastructure, hardware and software are available in the lab to start this research.

This PhD research will be undertaken under the supervision of Prof. Krishna Kumar Saxena and Prof. Dominiek Reynaerts in the Micro & Precision Engineering (MPE) research group, and in close collaboration with the postdoctoral researcher Dr. Muhammad Hazak Arshad. The MPE research group at the Department of Mechanical Engineering is a multidisciplinary team specialised in (micro)manufacturing, design and integration of advanced manufacturing systems with a focus on precision, miniaturisation and process intelligence. The vibration and environment controlled research labs are located in the Leuven Nanocenter with state-of-the-art of manufacturing, metrology and characterisation infrastructure. KU Leuven (University of Leuven) has been a center of learning for nearly six centuries since 1425, making it one of the oldest and most renowned universities in Europe. Today, it is Belgium’s highest ranked university (QS 2025 : 60), ranked among the top 4% universities in the world and consistently ranked in the top 10 most innovative universities in Europe. The university caters to over 60,000 students from more than 140 countries. KU Leuven's three doctoral schools provide internationally oriented PhD tracks for more than 4,000 doctoral students. KU Leuven and affiliated knowledge institutes provide fertile ground for innovation and high-tech entrepreneurship in the Leuven region. This favourable climate for knowledge-driven innovation makes the Leuven region an attractive location for many high-tech companies.

The start of PhD is planned for 1st November 2025 but is negotiable. The offer will include :