Overview
Shape the future of advanced materials discovery and join a pioneering project to transform flow chemistry into a dynamic, intelligent process. By integrating mechatronics, 3D printing, and advanced simulation to achieve real-time control over mixing and crystallisation, you’ll help create materials with precision and unlock breakthroughs in sustainable manufacturing.
About this opportunity
We have recently shown that tuning flow rate, temperature, and residence time can control particle size and morphology during flow crystallisation of fast-forming organic materials (Shaughnessy et al, 2023; Watson PhD thesis 2025). Extending this to control crystallinity is important for producing high-performance materials for selective separation of e.g., hydrogen isotopes (Liu et al, 2019).
However, current systems lack dynamic control over mixing – a critical factor in rapid crystallisation. In many lab flow set-ups, passive mixing occurs via static junctions (e.g. T-junctions) under steady laminar flow, where diffusion dominates. Adjusting mixing parameters requires physical changes to the setup, leading to downtime and limited flexibility.
This PhD project proposes a novel mechatronic system for real-time control of mixing by actively modifying inlet geometry and residence time. A variable-volume reactor will be designed using an actuated periscopic channel to dynamically adjust length and hence residence time. Inlet junctions will be 3D-printed in compliant resin, incorporating magnetically actuated flaps to alter geometry on demand. Numerical simulations will guide the design to optimise flow and mixing efficiency. The final system will be integrated into a commercial flow chemistry platform, offering continuous, fine-grained control over crystallisation reaction conditions. This will be demonstrated through the synthesis of porous materials with controlled particle size, morphology, and crystallinity, and with application in materials synthesis where mixing has influence over material formation (e.g., polymer nanoparticles, hierarchical materials, influencing nucleation/early stages of COF/MOF formation).
The project will be supervised by a diverse team with a strong track record on the key relevant topics.
Dr Paoletti (Department of Mechanical and Aerospace Engineering) is the founder of the @LERT robotics lab. His work spans automation and robotics across a wide variety of applications, with a particular focus on creation of novel mechatronic systems such as bespoke grippers for chemistry labs, large scale collaborative 3D printers, microfluidic sensing and actuation.
Prof Slater (Department of Chemistry) has extensive experience in the synthesis, characterisation, and crystallisation of organic materials and their precursors. Her work uses flow chemistry, automation, and novel reactors to optimise process conditions for functional materials. She collaborates extensively with industrial end-users of functional materials (Victrex, Baker Hughes, AtkinsRealis/NPL), bringing routes to impact for this research.
Prof Poole (Department of Mechanical and Aerospace Engineering) is an expert in non-Newtonian fluid mechanics and has interests in constitutive modelling, rheology, and microfluidic mixing devices. His expertise covers both numerical modelling and experimental testing of flow and mixing conditions.
This project is expected to start in October 2026 and is offered under the EPSRC Centre for Doctoral Training in Digital and Automated Materials Chemistry based in the Materials Innovation Factory at the University of Liverpool, the largest industry-academia colocation in UK physical science. The successful candidate will benefit from training in robotic, digital, chemical and physical thinking, which they will apply in their domain-specific research in materials design, discovery and processing. PhD training has been developed with 35 industrial partners and is designed to generate flexible, employable, enterprising researchers who can communicate across domains.
Supervisors
Candidates will have, or be due to obtain, a Master’s Degree or equivalent in Chemistry, Engineering, Materials Science, Physics, or related disciplines. Exceptional candidates with a First Class undergraduate degree or equivalent in an appropriate field will also be considered.
The minimum English Language requirements for international candidates is IELTS 6.5 overall (with no band below 5.5) or equivalent. Find out more about English language requirements.