Xiaolong Chen

Xiaolong is currently a PhD researcher at the University of Northampton, conducting his research under the supervision of Dr. Mahmoud Moradi (Associate Professor of Advanced Manufacturing Engineering) and Dr. Friedemann Schaber (Senior Lecturer in Product Design). His work focuses on the optimisation of functional composite filament manufacturing for Fused Deposition Modelling (FDM), specifically investigating the process parameters and microstructural characteristics of conductive PLA/TPU filaments. Through this research, Xiaolong aims to improve the performance of piezoresistive sensors to address industrial demands for low-cost, repeatable flexible sensors in wearable monitoring and soft robotics.

An accomplished engineer with nearly 20 years of experience, Xiaolong possesses a deep background in internal combustion engine and turbomachinery performance testing. Before his doctoral studies, he served as a Laboratory Engineer at Beihang University (Beijing) for over a decade. There, he applied FDM 3D printing technology to manufacture blades for turbomachinery experiments and led the development of a multi-channel micro-differential pressure tester, completing the task of measuring blade surface pressure distribution on a low-speed large-scale compressor test rig.

Xiaolong holds an MSc in Advanced Design and Manufacturing from the University of Northampton and an MSc in Power Machinery and Engineering from Beihang University. His unique background combines solid technical skills in process optimisation and experimental design with practical expertise in system R&D based on additive manufacturing technologies.

My research is deeply rooted in high-tech manufacturing processes, with a specific passion for Additive Manufacturing (AM) and process development. I am currently researching the optimisation of conductive FDM-printed sensors, moving beyond material formulation to focus on process parameter optimisation of commercial filaments.

My primary goal is to develop a parameter-microstructure-performance model that enhances the sensitivity and stability of 3D-printed sensors. Specifically, I am investigating:

• Process Optimisation: How nozzle temperature, print speed, and layer height influence the piezoresistive behaviour of PLA/TPU filaments.

• Microstructural Analysis: The relationship between layer adhesion, porosity, and surface roughness on sensor performance.

• Functional Application: Developing reliable sensors for structural health monitoring and flexible pressure sensing.

I utilise Design of Experiments (DOE) methodologies, such as Taguchi design, to methodically optimise printing parameters for scalable, high-performance fabrication.