Design School

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Dr Andrew Johnson

Photo of Dr Andrew Johnson

Lecturer in Industrial/Product Design

Dr. Andrew Johnson is a Lecturer in Product/Industrial Design and a member of the Design for Digital Fabrication research group within the Loughborough Design School.  Andrew holds a First Class BSc (Hons) degree in Industrial Design and a distinction level MSc in Rapid Product Development.

In 2010 Andrew joined Loughborough University to focus on doctoral research aimed at utilising Additive Manufacturing technologies for the development of stab resistant body armour.  This research was conducted under the supervision of Dr. Guy Bingham, and externally by Dr. Candice Majewski of the Advanced Additive Manufacturing (AdAM) group at the University of Sheffield.

Following the completion of his PhD, Andrew was employed as a Research Associate on the EU FP7 funded CassaMobile project.  In 2015, Andrew was appointed as a lecturer in Product/Industrial Design.  His research specialises in protective applications of Additive Manufacturing (AM) / 3D printing technologies, as well as process quality assurance within AM.  This research has won a number of awards sponsored by the Rapid Prototyping Journal (RPJ), UK Defence Safety & Security Committee, IOM3, and the Solid Freeform Fabrication conference.

  • DSA008 - Mechanics for Design
  • DSC021 - Design Research Dissertation
  • DSC026 - Final Year Design Practice

Research Group: Design for Digital Fabrication

The Design for Digitial Fabrication Research Group (D4DF) focuses on the aspects which support a range of automated, computer-controlled manufacturing processes to bring into physical reality, as well as the psychosocial and economic impacts of these processes.  This research focuses on the 3D Printing and Additive Manufacturing technologies but also encompasses 3D scanning, computer-aided design, and digital manufacturing process such as laser cutting and CNC machining.  The D4DF research group feeds into Loughborough University’s campus-wide Additive Manufacturing Research Group.

Dr. Johnson's personal research is focussed on the development and utilisation of Additive Manufacturing / 3D Printing technologies for high performance protective applications such as 3D-printed body armour.  This research focuses on the use of CAD, Additive Manufacturing technologies, and a range of machine vision hardware and software systems. 

Dr Johnson is also a co-investigator on a project entitled ‘CassaMobile’ – an €8.75M EU FP7 project involving 11 European partners.  The CassaMobile concept aims to provide local, flexible and environmentally friendly production of highly customised parts using a truly modular production system that is capable of rapidly adapting to new product and market requirements.  This ‘plug & produce’ architecture includes mechanical and control system adaptation.  The footprint of the CassaMobile production container is minimised to enable transportation to and deployment within areas with severely limited space, whilst minimising investment and infrastructure costs.  Further details relating to the ‘CassaMobile’ project can be found at:

  • Johnson, A. A., Bingham, G. A., & Majewski, C. E. (2016). Laser sintered body armour - establishing single layer stab protection. Rapid Prototyping Journal. (Awaiting Publication)
  • Johnson, A. A., Bingham, G. A., & Majewski, C. E. (2016). Comparing the penetrative stab performance of the UK HOSDB P1/B and Stanley Tools 1992 trimming blades on certified body armour specimens. The Police Journal: Theory, Practice and Principles. (Awaiting Publication)
  • Johnson, A. A., Zarezadeh, H., Han, X., Bibb, R., & Harris, R. (2016). Establishing In-Process Inspection Requirements for material Extrusion Additive Manufacturing. In Fraunhofer Direct Digital Manufacturing Conference. Berlin.
  • Johnson, A. A., Bingham, G. A., & Majewski, C. E. (2015). Laser Sintered body armour - establishing guidelines for dual-layered stab protection. International Journal of Rapid Manufacturing. doi: 10.1504/IJRAPIDM.2015.073545
  • Johnson, A., Bingham, G. A., & Wimpenny, D. I. (2013). Additive manufactured textiles for high-performance stab resistant applications. Rapid Prototyping Journal, 19(3), 199-207. doi:10.1108/13552541311312193
  • Johnson, A., Bingham, G. A., & Majewski, C. E. (2012). Establishing the performance requirements for stab-resistant Additive Manufactured Body Armour (AMBA). In Solid Freeform Fabrication Symposium (pp. 1-10). Texas, USA.
  • Johnson, A., Bingham, G. A., & Wimpenny, D. I. (2011). Additive manufactured textiles for high-performance stab resistant applications. In RDPM 2011 - 12th Rapid Design, Prototyping & Manufacturing Conference (RDPM 12) (pp. .). Lancaster University.

Key areas of expertise: Additive Manufacturing / 3D Printing; Rapid Prototyping; High Performance Additive Manufacturing; 3D Printed Body Armour; Composite Additive Manufacturing; Machine Vision; Process Inspection; Design for Additive Manufacturing; Computer-Aided Design; Advanced Product Design