Background:
Francesco Careri holds a BSc and MSc in Mechanical Engineering from the University of Calabria (Italy), where he developed a strong foundation in advanced manufacturing processes and computational modelling. His MSc research focused on hybrid additive manufacturing and post-processing strategies for nickel-based superalloys, combining experimental investigations with finite element modelling to study surface integrity, residual stresses, and thermo-mechanical behaviour. During this period, he also undertook a visiting research placement at the University of Birmingham, UK, where he gained hands-on experience in metal additive manufacturing and microstructural characterisation of aerospace alloys.
He completed his PhD with Integrated Study in Topological Design at the University of Birmingham, UK, within the School of Metallurgy and Materials. His doctoral research was sponsored by the Centre for Doctoral Training in Topological Design and the National Structural Integrity Research Centre (NSIRC) at TWI Ltd. His research focused on the development of additive manufacturing and post-processing strategies for high-strength aluminium alloys, with particular emphasis on laser powder bed fusion, thermal management applications, and the digital optimisation of complex geometries such as heat exchangers. His work integrated materials science with machine learning to establish process–microstructure–property relationships and enable data-driven manufacturing optimisation.
Following his doctoral studies, Francesco continued at the University of Birmingham as a Research Assistant and later as a Research Fellow, working on near net shape manufacturing technologies and digital manufacturing integration. In these roles, he contributed to multiple research projects involving experimental process development, advanced characterisation, and computational analysis, while also managing project activities, coordinating collaborations with industrial partners, and supervising MSc and PhD students.
He is currently a Research Associate at Loughborough University, where his research focuses on digital engineering approaches for advanced manufacturing, including data-driven process optimisation, intelligent materials processing, and sustainable manufacturing technologies. His work supports interdisciplinary collaboration across materials science, manufacturing engineering, and artificial intelligence, contributing to the development of next-generation digital and high-value manufacturing systems.
Qualifications:
- PhD with Integrated Study in Topological Design, University of Birmingham, UK
Awarded with no corrections. Research focused on additive manufacturing and post-processing strategies for high-strength aluminium alloys, integrating materials science with machine learning, reinforcement learning, and digital optimisation methods for advanced manufacturing and thermal management applications. - MSc Mechanical Engineering (First Class Honours), University of Calabria (UNICAL), Italy
Experimental thesis on hybrid additive manufacturing and post-processing strategies for nickel-based superalloys, combining experimental characterisation and finite element modelling to investigate surface integrity, residual stresses, and thermo-mechanical behaviour. - BSc Mechanical Engineering, University of Calabria (UNICAL), Italy
Thesis focused on finite element modelling of machining processes, specifically orthogonal cutting of additively manufactured Ti-6Al-4V alloys, with emphasis on thermo-mechanical behaviour and material response during machining.
Outline of main research interests:
Francesco’s research interests focus on the integration of materials science, advanced manufacturing, and digital engineering to develop sustainable, high-value manufacturing technologies. In particular, his research focuses in understanding and controlling process–microstructure–property relationships through a combination of experimental investigation and data-driven modelling.
Key research interests include:
- Additive Manufacturing of Metallic Materials
Laser powder bed fusion and hybrid manufacturing processes for advanced metallic alloys, with emphasis on manufacturability, defect control, and performance optimisation. - Digital and Data-Driven Manufacturing
Application of machine learning, reinforcement learning, computer vision, and physics-informed models to optimise manufacturing processes, support digital twins, and enable intelligent process control. - Post-Processing and Surface Engineering
Development of heat treatments, hot isostatic pressing (HIP), and surface modification techniques (e.g. plasma electrolytic oxidation) to tailor microstructure, mechanical properties, and surface performance. - Microstructure–Property Relationships
Advanced characterisation and modelling to link processing conditions with microstructural evolution and mechanical behaviour, including fatigue, creep, wear, and corrosion performance. - Thermal Management Systems and Lightweight Design
Design and manufacture of advanced heat exchangers and thermal management components using additive manufacturing to reduce weight and improve efficiency in aerospace and automotive applications. - Near Net Shape and Sustainable Manufacturing
Process design and optimisation for resource-efficient manufacturing routes, reducing material waste, energy consumption, and environmental impact.
Teaching and Mentorship:
Francesco has contributed to teaching primarily through laboratory-based and research-led activities in advanced manufacturing and materials engineering. In addition to laboratory teaching, he has supervised and co-supervised MSc and PhD students, supporting them in the definition of research topics, experimental planning, data analysis, and dissertation or thesis preparation.
His supervisory role continues in his current position at Loughborough University, where he actively mentors postgraduate researchers (MSc and PhD students) and contributes to their technical and professional development.
Publications:
- Francesco Careri, Stano Imbrogno, Moataz M. Attallah, Khamis Essa, Domenico Umbrello, (2020): “Finite Element Modeling of Machining Nickel Superalloy Produced By Direct Energy Deposition Process”, Procedia Manufacturing, 47:525-529. https://doi.org/10.1016/j.promfg.2020.04.120
- Francesco Careri, Stano Imbrogno, Domenico Umbrello, Moataz M. Attallah, José Outeiro, António C. Batista (2020): “Machining and Heat Treatment as Post-Processing Strategies for Ni-Superalloys Structures Fabricated using Direct Laser Deposition”, Journal of manufacturing Processes, 61:236-244. https://doi.org/10.1016/j.jmapro.2020.11.024
- Francesco Careri, Domenico Umbrello, Khamis Essa, Moataz M. Attallah, Stano Imbrogno (2020): “The Effect of the Heat Treatments on the Tool Wear of Hybrid Additive Manufacturing of IN718, Wear, 470-471, 203617. https://doi.org/10.1016/j.wear.2021.203617.
- Francesco Careri, Stano Imbrogno, Domenico Umbrello, José Outeiro, António C. Batista (2021): “A Residual Stress Prediction of Machining IN718 Produced by Direct Energy Deposition”, Procedia CIRP 102, 13–18. https://doi.org/10.1016/j.procir.2021.09.003 .
- Francesco Careri, Raja H. U. Khan, Catherine Todd, Moataz M. Attallah (2023): “Additive Manufacturing of Heat Exchangers in Aerospace Applications: A Review”, Applied Thermal Engineering, 121387. https://doi.org/10.1016/j.applthermaleng.2023.121387
- Michele De Lisi, Francesco Careri, Usama M Attia, Khamis Essa (2024): “Effect of different additives and sintering regimes on the optical properties of DLP printed translucent alumina”, Ceramics International, Vol. 50, issue 14, pp. 26065-26076. https://doi.org/10.1016/j.ceramint.2024.04.348.
- Francesco Careri, Alessandro Sergi, Pavel Shashkov, Raja HU Khan, Moataz M Attallah (2024): “Plasma electrolytic oxidation (PEO) as surface treatment for high strength Al alloys produced by L-PBF: Microstructure, performance, and effect of substrate surface roughness”, Surface and Coatings Technology, 131122. https://doi.org/10.1016/j.surfcoat.2024.131122.
- Alessandro Sergi, Raja HU Khan, Francesco Careri, Hugh Hamilton, Martina Meisnar, Advenit Makaya, Moataz M Attallah (2024): “Diffusion bonding of dissimilar materials for space applications via hot isostatic pressing”, Materials Letters, Vol. 376, 137260. https://doi.org/10.1016/j.matlet.2024.137260.
- Ahmed M Faizan Mohamed, Francesco Careri, Raja HU Khan, Moataz M Attallah, Leonardo Stella (2024): “A novel porosity prediction framework based on reinforcement learning for process parameter optimization in additive manufacturing”, Scripta Materialia, Vol. 255, 116377. https://doi.org/10.1016/j.scriptamat.2024.116377.
- Francesco Careri, Raja HU Khan, Talal Alshammari, Moataz M Attallah (2025): “Development of a novel heat treatment in L-PBF fabricated high strength A205 Al alloy: Impact on microstructure-mechanical properties”, Materials Science and Engineering: A, Vol. 993, 148278. https://doi.org/10.1016/j.msea.2025.148278.
- Francesco Careri, Leonardo Stella, Raja H. U. Khan, Moataz M. Attallah (2025): “Application of machine learning in additive manufacturing of a novel Al alloy heat exchanger”, The International Journal of Advanced Manufacturing Technology, Vol. 137, 4557 - 4572. https://doi.org/10.1007/s00170-025-15389-y.
- Tugrul Talha Ersoz, Francesco Careri, Stano Imbrogno (2025): 1 - Fundamentals of additive manufacturing techniques, Editor(s): Moataz M. Attallah, Abd El-Moez A. Mohamed, In Additive Manufacturing Materials and Technologies, Additive Manufacturing of Magnetic Materials, Elsevier, Pages 3-28, ISBN 9780443333958. https://doi.org/10.1016/B978-0-443-33395-8.00010-0.