Advanced Litz Wire Modelling and Manufacturing for Ultra-High Speed Propulsion Motors

This project is an exciting opportunity to undertake industrially linked research in partnership with the Manufacturing Technology Centre (MTC). It is based within the Power Electronics, Machines and Control (PEMC) Research Institute in the Faculty of Engineering at the University of Nottingham, which amongst its internationally renowned research portfolio, conducts cutting edge research into the development of future Power Electronics and Electrical Motor Drives Systems.

Vision

We are seeking a highly motivated PhD student to conduct cutting-edge research with support from state-of-the-art electric motor manufacturing platforms both at the MTC and the PEMC Institute. Based on the emerging Litz wire winding technology, this PhD project will focus on multi-physics modelling and characterisation of “programmable” Litz wires. By leveraging the MTC's exclusive high-spec braiding machine this research has the vision of significantly enhancing the design and manufacturing process of Litz wire winding for next-generation high-spec electric propulsion systems.

Motivation

The ambitious roadmaps of electrification in high-performance propulsion applications are pushing the boundary of electric motor speed, especially in motorsport and aviation sectors. Achieving ultra-high speed motor operation demands advanced winding solutions capable of handling elevated frequencies and corresponding AC losses. Litz wire, with its unique capability in AC loss mitigation, is pivotal for pushing motor’s efficiency and power density. Meanwhile, its design-stage modelling, encompassing power losses, thermal behaviour, and mechanical integrity, remains at early stage. Current practices are limited in capturing the layout complexity and manufacturing flexibility of Litz wire against its multi-physics performance variation. Addressing these challenges based on the MTC's world-class wire braiding machine offers an exciting PhD opportunity, to revolutionise Litz wire winding development, and accelerate advancements in high-speed propulsion technologies.

PhD project description

The project will focus on developing rapid modelling tools capable of delivering high-fidelity predictions of Litz wire performance across multiple physics. This tool will account for wide range of layout construction options enabled by the MTC’s state-of-the-art programmable Litz wire manufacturing platform. The research will providing a robust framework for integrating this advanced winding manufacturing technology into next-generation ultra-high speed propulsion systems.

The PEMC Institute is home to Driving the Electric Revolution Midlands Industrialisation Centre and the UK Electrification of Aerospace Propulsion Facilities, which have received over £20m of funding in the last three years. This 5000m2 institute with state-of-the-art facilities for research into electrification technologies, hosting 21 academics, 60 post-doctoral researchers and over 80 PhD students, will be made available for this PhD project. 

As a PhD student you will work with academics from the PEMC Institute and have the opportunity to work with the engineering teams within the MTC. This will give you real-world experience in working within an industrial company, as well as experiencing the workplace and culture within it. 

Funding

This is a three year fully funded studentship open to UK “home” students only. The successful applicant will receive a generous tax-free annual stipend of £25,000 plus payment of their full-time home tuition fees. An additional £2,000 per annum is provided for consumables and travel. As this position is sponsored by the MTC, the successful candidate would need to pass the sponsors own security checks prior to the commencement of the PhD.

Candidate requirements

• An enthusiastic, self-motivated candidate with a 1st or high 2:1 degree in electrical / mechanical engineering, physics, mathematics, or related scientific disciplines
• It is desirable that the candidate has demonstrated skills in numerical tools and good programming skills (MATLAB, python, C++ etc)
• Any experience or capabilities in engineering design or manufacturing methods would be advantageous

Eligibility and how to apply

• Due to funding restrictions the position is available for UK candidates only
• Project start date: 1 October 2025 
• Closing date for applications: 28 February 2025
• For further information on this PhD studentship email Professor Chris Gerada (University of Nottingham) and Dan Walton (MTC)

The university actively supports equality, diversity and inclusion and encourages applications from all sections of society. We provide a thriving working environment for all our postgraduate researchers (PGRs) creating a strong sense of community across research disciplines. Community and research culture is important to our PGRs. We support this by working closely with our Postgraduate Research Society and our PGR research group represpentatives to enhance the research environment for PGRs. You'll benefit from training through the Researcher Academy’s training programme, with those based within the faculty able to access bespoke courses developed specifically for engineering PGRs including sessions on paper writing, networking, and career development after your PhD. We have outstanding facilities and work in partnership with leading industrial partners.

The MTC is an independent Research and Technology Organisation (RTO) aimed at de-risking and accelerating the adoption of disruptive technologies within the UK manufacturing sphere. Supported by the UK government, the MTC works closely with industrial partners and other research organisations to deliver world leading innovation across all levels of the UK’s industrial landscape, from SMEs and start-ups to OEMs and large-scale global manufacturers