School staff

Dr Andrew Johnson

Photo of Dr Andrew Johnson

Lecturer in Product Design

Dr. Andrew Johnson is a Lecturer in Product 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 Design where his research has specialised on the use of Additive Manufacturing and 3D Printing technologies for protective applications.  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.

DSA006 – Prototyping for Design

DSA008 – Mechanics for Design

DSA201 – Design Research & Professional Practice

DSA202 – Prototyping for Evaluation

DSC026 – Final Year Design Practice

DSP872 – Design for Commercialisation

DSP873 – Design for Additive Manufacturing Research Project

Research Group: Design for Digital Fabrication

Dr. Johnson's 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. 

In 2018, Dr. Johnson was awarded an EPSRC New Investigator grant to lead a project seeking to disrupt and enhance the performance of current body armour solutions – ‘Hybrid Additive Manufactured-Aramid fibre body armour’. The aim of this project was to utilise the design and manufacturing opportunities offered by AM technologies, coupled with the enhanced protective performance and manoeuvrability of existing aramid-based armour. The development of a hybrid protective system could present a significant leap in the development of the next generation of body armour in which the physical comfort of the wearer and their subsequent operational performance is as important a factor as protective performance.

Between 2014-2016, Dr Johnson was a co-investigator on a project entitled ‘CassaMobile’ – an €8.75M EU FP7 project involving 11 European partners.  The CassaMobile concept aimed 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 included mechanical and control system adaptation.  The footprint of the CassaMobile production container was minimised to enable transportation to and deployment within areas with severely limited space, whilst minimising investment and infrastructure costs.  Further details relating to the outcomes of the ‘CassaMobile’ project can be found at:

Dr. Johnson is an active member of the Design for Digital Fabrication Research Group (D4DF).  This research group supports the utilisation of a wide range of Additive Manufacturing and 3D printing processes for social and economic impacts.  Such work encompasses the use of 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.

Adamietz, R., Giesen, T., Mayer, P., Johnson, A.A., Bibb, R., and Seifarth, C. (2018). Reconfigurable and transportable container-integrated production system. Robotics and Computer-Integrated Manufacturing.53pp. 1 - 20. DOI: 10.1016/j.rcim.2018.02.008

Johnson, A.A., Bingham, G.A., and Majewski, C.E., (2018). The design and assessment of bio-inspired additive manufactured stab-resistant armour. Virtual and Physical Prototyping.13 (2), pp. 49 - 57. DOI: 10.1080/17452759.2017.1369438

Johnson, A.A., Bingham, G.A., and Majewski, C.E (2018). Laser sintered body armour – establishing single layer stab protection. Rapid Prototyping Journal. DOI: 10.1108/RPJ-11-2015-0173

Johnson, A.A., Bingham, G.A., and 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.90 (1). DOI: 10.1177/0032258X16671029

Johnson, A.A, Bingham, G.A and Majewski, C.E, (2015). Laser Sintered body armour - establishing guidelines for dual-layered stab protection. International Journal of Rapid Manufacturing.5 (1). DOI: 10.1504/IJRAPIDM.2015.073545

Johnson, A.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

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