AI/ML Research Engineer, Additive Manufacturing (KTP Associate)

An exciting opportunity has become available to work on a 36-month Knowledge Transfer Partnership (KTP) between the University of Exeter and Rapid Fusion Ltd. The KTP will develop AI‑enabled software for intelligent process control in Large Format Additive Manufacturing (LFAM), focused on improving polymer deposition consistency and interlayer bonding performance.

The successful candidate will be employed by the University of Exeter and will spend the majority of their time working at Rapid Fusion Ltd in Exeter, with occasional visits to the University of Exeter. They will be expected to work full-time.

To develop AI-enabled software that improves the reliability and strength of Large Format Additive Manufacturing systems for Rapid Fusion. The project will enable higher-value product sales, software licensing, and new services, while reducing waste and supporting wider industrial adoption of large-scale polymer 3D printing.

The KTP Associate will be embedded within Rapid Fusion Ltd (RF), to deliver the project objectives by:

• Lead the development of AI-enabled software for intelligent process control in Large Format Additive Manufacturing (LFAM) focused on improving polymer deposition consistency and inter-layer bonding performance.
• Investigate and model polymer flow, thermal behaviour and inter-layer bonding to improve print quality and mechanical performance.
• Design and implement data-driven, adaptive control algorithms to optimise LFAM process parameters in real time.
• Integrate sensor data into AI models to predict print quality, bonding performance and defect formation.
• Validate models using materials characterisation and process data.
• Translate research outputs into robust, deployable software tools for Rapid Fusion Ltd LFAM systems.
• Work closely with company engineers to embed new knowledge and capabilities into manufacturing workflows.
• Contribute to knowledge transfer, documentation and reporting in line with Innovate UK KTP requirements.

This project will enable Rapid Fusion Ltd to improve current processes and to enable future innovations and products to accelerate its strategic goals.