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Debajyoti Bhaduri

Dr Debajyoti Bhaduri


School of Engineering

+44 29225 10922
Queen's Buildings - West Building, Room Room W/2.21, 5 The Parade, Newport Road, Cardiff, CF24 3AA
Available for postgraduate supervision


Dr Debajyoti Bhaduri is a Lecturer in High-Value Manufacturing within the School of Engineering of Cardiff University. His research interest broadly centres on the advanced machining / grinding, laser-based micro-manufacturing and metal additive manufacturing (AM), hybrid manufacturing technologies, such as ultrasonic assisted machining / grinding, surface engineering via physical vapour deposition (PVD) coating, laser texturing, and laser polishing.

Prior to joining Cardiff University, Dr Bhaduri has been involved in several European projects as a Research Fellow in the University of Birmingham between 2013-2018 that focussed on development and implementation of hybrid manufacturing process chains, incorporating various pre- and post-processing steps of metallic AM parts. During his PhD, he developed a novel hybrid ultrasonic assisted creep feed grinding process for machining of advanced aerospace alloys such as Inconel 718, CMSX-4 and gamma titanium aluminide.

Dr Bhaduri's current research activity centres on developing novel circular manufacturing routes for the production of sustainable powders for metal AM. The research enables synergistic study on the sustainability of AM processes and their environmental impact from the life-cycle perspective. His research expertise also encompasses various surface and material characterisation techniques via roughness, microhardness, microstructure and different microscopic and spectroscopic (EDS, WDS, EMPA, SIMS, XPS, OES and XRD) analysis.





















Research Interests:

Dr Debajyoti Bhaduri is currently undertaking research in the following areas:

  • Circular Hubrid Manufacturing (CHM) - The research focuses on the development of novel circular manufacturing routes for the production of sustainable powders for metal additive manufacturing (AM). The research enables synergistic study on the sustainability of AM processes and their environmental impact from the life-cycle perspective. The research strategy aligns with the UK Government's 'Net Zero' target, with the aim to dramatically reduce the carbon footprint of the current AM powder production techniques and to foster recycle of materials to produce high-value AM parts.
  • Development of Hybrid Manufacturing Process Chains - The research involves AM process optimisation for new metallic materials, followed by post-processing of the AM parts via laser-based surface engineering techniques, such as laser polishing and laser surface texturing, to improve the built parts' surface integrity.
  • Surface texturing via mechanical micromilling - This is a complementary surface engineering technique to the laser surface texturing (LST). Comparative surface integrity analyses are undertaken on the parts, textured via mechanical micromilling and LST.
  • Machining of metal-composites stacks - The effects of single-shot milling of metal-composite (e.g. Al/CFRP) stacks are investigated on the workpieces' surface integrity and cutting tool wear.

Research publications:

Research Grants:

Title People Sponsor Role Amount Duration
Evaluation of hybrid additive-subtractive metallic parts D Bhaduri University of Birmingham PI £6,400 2018-2021
Evaluation of the interrelation between key process parameters and product/material properties in a hybrid additive-subtractive process chain D Bhaduri, R Setchi, M Ryan, A Kundu EPSRC DTP Lead £55,382 2019-2023

Surface integrity analysis of selective laser melted AlSi10Mg alloy following laser polishing

D Bhaduri

Shri Gopal Rajgarhia International Programme (SGRIP), IIT Kharagpur, India

PI INR 196,000 2019

Early Career Researcher Fund

D Bhaduri

School of Engineering, Cardiff University

PI £13,169 2021

A metal binder jetting machine

D Bhaduri et al.

Higher Education Funding Council for Wales (HEFCW)

PI £350,400 2022-2023

Architectural microstructure-modification mechanisms and the microstructure-performance optimization for SLM Aluminum matrix composites

R Setchi, D Bhaduri, M Ryan, P Wang

The Royal Society - International Exchanges 2021

Co-I £12,000 2022-2024

Research Boost Fund

D Bhaduri

School of Engineering, Cardiff University

PI £41,400 2022

Re-engagement Fund

D Bhaduri

School of Engineering, Cardiff University

PI £5,000 2022

From waste to worth: A pilot study on the circular manufacturing of sustainable additive manufacturing powders from machining scraps

D Bhaduri

Net Zero Innovation Institute Seedcorn Project

PI £10,000 2022

Circular Hybrid Manufacturing (CHM) of sustainable powders for powder-bed-fusion additive manufacturing (AM) processes via recycling of machining scraps

D Bhaduri

Sêr Cymru programme  Enhancing Competitiveness Equipment Awards

PI £67,670 2022-2023

Novel antimicrobial and regenerative laser-textured bulk metallic glass implant surfaces

W N Ayre, D Bhaduri, E Brousseau, S Bigot


Joint-lead £81,924 2023-2026

Equipment enabling atomic-resolution imaging of electrochemical processes: from catalysis to medicine

T Slater et al.

Higher Education Funding Council for Wales (HEFCW)

Co-I £242,020 2023-2024

Synthesis and evaluation of titanium powders for additive manufacturing of cutting tools from recycled titanium chips

D Bhaduri, S Gangopadhyay, J Immanuel R

Scheme for Promotion of Academic and
Research Collaboration (SPARC), India

PI INR 5,769,125 2023-2025

From Waste to worth: Circular production of sustainable additive manufacturing powders from machining scraps

D Bhaduri

Taith Research Mobility Grant, Welsh Government

PI £3,160 2023-2024


  • Advanced manufacturing technologies
  • Industrial project management


  • Lecturer (current post):  School of Engineering, Cardiff University, Cardiff, UK
  • Research Fellow (2013-2018):  School of Engineering, Department of Mechanical Engineering, University of Birmingham, Birmingham, UK
  • Honorary Senior Research Fellow (2018-present):  School of Engineering, Department of Mechanical Engineering, University of Birmingham, Birmingham, UK
  • PhD (2010-2014):  School of Mechanical Engineering, University of Birmingham, Birmingham, UK
  • Assistant Professor (2009): National Institute of Technology Rourkela, India
  • Master of Technology (2007-2009):  Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, India
  • Bachelor of Engineering (2003-2007):  Department of Production Engineering, Jadavpur University, Kolkata, India

Honours and awards

  • Al Sonntag award for the best paper on solid lubricants subject, awarded by the Society of Tribologists and Lubrication Engineers (stle) (2019)
  • Joseph Whitworth Award for the best paper on a manufacturing industries mechanical engineering subject, awarded by the Institution of Mechanical Engineers (2017)
  • Institute Silver Medal, awarded by Indian Institute of Technology Kharagpur, India (2009)
  • B. M. Belgaumkar Memorial prize, awarded by Indian Institute of Technology Kharagpur, India (2009)
  • University Gold Medal, awarded by Jadavpur University, India (2007)

Professional memberships

  • Research Affiliate of the CIRP
  • Fellow of the Higher Education Academy (FHEA)

Speaking engagements

  • Keynote speech at the International Conference on Recent Advances in Mechanical Infrastructure (ICRAM-2022), organised by IITRAM Ahmedabad and IIT Bhilai, India.

Committees and reviewing

  • Scientific Committee Member:

         - 5th CIRP Conference on Surface Integrity (CSI) 2020.
         - Cardiff School of Engineering Research Conference 2023.
         - Sustainable Design and Manufacturing Conference, SDM 2023.
         - 11th CIRP Global Web Conference, CIRPe 2023.

  • Journal reviewer: Applied Surface Science, Ceramics International, CIRP Journal of Manufacturing Science and Technology, I. Mech. E.- Part B Journal of Engineering Manufacture, International Journal of Advanced Manufacturing Technology, Journal of Manufacturing Processes, Journal of Cleaner Production, Machining Science and Technology, Manufacturing Letters, Materials and Manufacturing Processes, Measurement, Precision Engineering, Surface and Coatings Technology, Ultrasonics, Wear.
  • PhD theses reviewer:  
Name of the PhD student Year of review University/Institution
Markus Hofele 2023 Glasgow Caledonian University, UK
Gaurav Dinkar Sonawane 2020 Dr. Babasaheb Ambedkar Technological University, Lonere, India
Anshuman Das 2019 National Institute of Technology Rourkela, India


I am interested in supervising PhD students in the areas of:

  • Metal additive manufacturing - process optimisation, circular manufacturing, hybrid manufacturing
  • Laser surface texturing, Laser polishing
  • Laser-based micromachining
  • Conventional machining (turning, milling, grinding)
  • Evaluation of the machinability of materials

Self-funded PhD projects

Self-funded PhD projects are advertised on Interested PhD applicants should submit an application for postgraduate study via the Cardiff University webpages ( 

Applicants should select Doctor of Philosophy (Engineering), with a start date of 1st October 2022/2023, 1st April 2023, or 1st July 2023.

The links to the self-funded PhD projects are given below.

1. A novel approach to the circular production of sustainable powders for metal additive manufacturing.

2. Circular hybrid manufacturing involving metal binder jetting process

3. A comparative study between binder jetting and powder bed fusion additive manufacturing processes for metallic materials

4. Developing an ingenious hybrid additive-subtractive manufacturing route for producing biomedical implants by combining powder bed fusion and laser post-processing techniques

5. Design and development of next generation textured cutting tools for improved tribological properties during machining.

6. Development of next generation electrosurgery electrode design via surface microtexturing.

PhD Scholarship opportunities for candidates from INDIA

National Overseas Scholarship, Department of Social Justice and Empowerment Ministry of Social Justice and Empowerment, Government of India.

Scholarship for SC students to study abroad, Social Justice and Special Assistance Department, Government of Maharashtra, India.

MP Foreign Study Scholarship, Department of Backward Classes and Minorities Welfare, Madhya Pradesh (MP), India.

Ambedkar Overseas Vidya Nidhi, SC Development; Ambedkar Overseas Vidya Nidhi, ST Welfare; Chief Minister's Overseas Scholarship Scheme for Minorities; Mahatma Jyothiba Phule Overseas Vidya Nidhi for BC and EBC students.

Current supervision

Ben Mason

Ben Mason

Research student

Peishan Zheng

Peishan Zheng

Research student

Research themes


  • Additive manufacturing
  • Machining
  • Laser micromachining
  • Surface engineering