Specialist Subjects: Micro manufacturing, micro electrical discharge machining, polymer processing, length scale integration, lean manufacture, process design, surface activation, biomimetics

My main research focus lies within the field of Micro and Nano Technology (MNT).

The focus of my PhD studies at the Manufacturing Engineering Centre, Cardiff University was Micro Manufacturing. In particular, micro electrical discharge machining for application within the production of micro injection mould tooling and micro component manufacture.

I have undertaken MNT research under EU FP6, FP7, EPSRC, TSB, WEFO and A4B funding programmes. My research activity is coupled by 8 years of industrial experience within both the automotive and medical device & diagnostic sectors.

As a result I possess a strong technical and practical background within the fields of injection moulding tooling design/manufacture, surface activation and lean manufacture.

In addition, I am a Chartered Engineer (MIMechE) and a Fellow of the Higher Education Academy.

Publications

  1. O’Sullivan, R., Rees, A., Griffiths, C., Wadlinger, J., Rees, A., Griffiths, C. A Study on the Modeling and Simulation of Bio-inspired Hedgehog Spines Structures for More Efficient Use Digital Manufacturing Processes (Ed.), Sustainable Design and Manufacturing 2019 375 385 Singapore Springer Link
  2. Llewelyn, G., Rees, A., Griffiths, C., Scholz, S., Rees, A., Griffiths, C. Advances in Near Net Shape Polymer Manufacturing Through Microcellular Injection Moulding (Ed.), Near Net Shape Manufacturing Processes 177 189 Springer
  3. Griffiths, C., Howarth, J., De Almeida-Rowbotham, G., Rees, A., Kerton, R., Rees, A., Kerton, R. A design of experiments approach for the optimisation of energy and waste during the production of parts manufactured by 3D printing Journal of Cleaner Production 139 74 85
  4. Williams, E., Brousseau, E., Rees, A., Rees, A. Nanosecond Yb fibre laser milling of aluminium: effect of process parameters on the achievable surface finish and machining efficiency The International Journal of Advanced Manufacturing Technology 74 5-8 769 780
  5. Griffiths, C., Tosello, G., Dimov, S., Scholz, S., Rees, A., Whiteside, B. Characterisation of demoulding parameters in micro-injection moulding Microsystem Technologies 21 8 1677 1690

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Teaching

  • EG-233 Placement Preparation: Engineering Industrial Year

    This generic cross-disciplinary module is for all students who have enrolled (or transferred) onto the Engineering Year in Industry scheme. The module focuses on the underpinning and fundamental requisites required to gain, enter and progress effectively through an industrial placement. Learners will be introduced to a) sourcing placements, CV writing and application techniques; (b) interview techniques - how to pitch yourself and be successful; (c) workplace fundamentals and IP awareness, behaviours and expectations; (d) key employability skills; getting the most from your Industrial Placement; and (e) health and safety in the workplace.

  • EG-239 Manufacturing Technology I

    Manufacturing makes a major contribution to the world economy and, engineering processes help solve some of the most serious challenges facing society today. The role of engineers in the manufacturing sector is crucial to generate sustainable high economic value products and jobs. To meet this ever-changing role, new graduates require an understanding of established and advanced processes. The module provides students with a holistic view of current, emerging and integrated manufacturing processes, providing a wide range of techniques required for producing product specifications based on process/technology selection. The taught material builds together with knowledge gained from materials and design modules. The topics are delivered by means of traditional lectures in each of the areas below

  • EG-281 Polymers: Structure and Processing

    The module will explore the link between the processing methods, structure and mechanical properties of polymers and polymer-based composites. This will give the students a good understanding and knowledge about the effects of structure and properties on the behaviour of these materials.

  • EG-365 Manufacturing Optimisation

    The module provides an introduction to the philosophy and tools used within the Lean Six Sigma methodology. The module will provide an overview of the Toyota Production System (TPS) and the quality systems applicable within manufacturing.

  • EG-M106 Polymer Processing

    The module will provide a deeper understanding of the technology of plastics processing. The material covered will cross cut the engineering disciplines of advanced manufacturing technology and polymer science to broaden the technical and industrial context of polymer processing. Within the content of the module simulation software will be applied to industrial case study examples for critical evaluation. In addition, the application of polymer replication technologies within the emerging field of micro manufacturing will be presented, focusing on the advantage and limitations of size effect and length scale integration. The module will include practical demonstration laboratories and also include industrial visits.

  • EG-M108 Advanced Polymers & Composites

    The module will provide a deeper understanding of the technology of plastics & composites materials and processing. The material covered will cross cut the engineering disciplines of advanced manufacturing technology and polymer science to broaden the technical and industrial context of polymer and composite processing. Within the content of the module simulation software will be applied to industrial case study examples for critical evaluation. In addition, the module will also introduce micro injection moulding, composite layups and 3-D printing.

  • EGA334 Mechanical Engineering Design 3

    This module demonstrates the outcomes of three years of learning and applies multiple skills to a design project. The project will show that students can manage and deliver a design task, as a team, through all stages of the design process. Students should progress from specification to concept design, undertake analysis (using computer tools as appropriate) and produce a design report and assembly drawings.

Supervision

  • Untitled (current)

    Student name:
    EngD
    Other supervisor: Dr Jennifer Thompson
  • Production of components through microcellular processing (current)

    Student name:
    EngD
    Other supervisor: Dr Christian Griffiths
  • Rapid prototyping and tooling of automotive seal mouldings (current)

    Student name:
    MSc
    Other supervisor: Prof Cris Arnold
  • Advanced Manufacturing Techniques of Implantable Blood Pumps (current)

    Student name:
    EngD
    Other supervisor: Prof Nicholas Lavery
  • Advanced Composite Manufacturing of Wind Turbine Blades and Shield (awarded 2019)

    Student name:
    MSc
    Other supervisor: Mrs Rhian Kerton
  • Control of Crease Generation on Polymer Laminated Steel (awarded 2019)

    Student name:
    MSc
    Other supervisor: Dr David Warren
  • 'Research into the development of methodologies for enhanced and sustainable profitability in injection moulding' (awarded 2018)

    Student name:
    MSc
    Other supervisor: Dr Christian Griffiths
  • 'Optimising material boding performance in a new generation of ultrasonic sensors' (awarded 2018)

    Student name:
    MSc
    Other supervisor: Dr Elizabeth Sackett

Administrative Responsibilities

  • Portfolio Director - Mechanical Engineering

    2016 - Present

Key Grants and Projects

  • Materials and Manufacturing Academy (M2A) 2016

    WEFO – Co-Investigator £1,652,500