Dr Felicity Freeman

Department of Materials Science and Engineering

Research Associate


Full contact details

Dr Felicity Freeman
Department of Materials Science and Engineering
Sir Robert Hadfield Building
Mappin Street
S1 3JD

Felicity is a post-doctoral research associate working on metal additive manufacturing. Her current research uses in-process monitoring capability to reduce process variation and enable localised control for material functionalisation. This builds on her industrial experience in process improvement and her skills in data analysis and signal processing. She works across the two most widely-used metal additive platforms; improving mechanical homogeneity in components built by Direct Energy Deposition through the application of closed-loop control, and creating architectured 4D metamaterials on Laser Powder-Bed Fusion, where she is exploiting material phenomena to create new types of programmable matter.

Felicity joined the department as a PhD student in 2015, working on the development of magnetically-graded steels, using the Laser Powder-Bed Fusion additive manufacturing process. This work led her to identify new routes for microstructural control in additively manufactured components, and she was awarded the University of Sheffield Brunton medal and the European Powder Metallurgy Association doctoral thesis award.

Prior to moving to Sheffield, she spent a decade as a Manufacturing Engineer at Rolls-Royce plc, working on the single-crystal casting of nickel super-alloy turbine blades. Her roles there included the certification of new products and casting process modelling, and most recently she was the Metrology Lead for the Advanced Blade Casting Facility at Rotherham, where she introduced non-contact measurement capabilities for the dimensional inspection of turbine blades. She is a Chartered Engineer with the IoM3, and holds an MSci in Materials Science & Metallurgy and MA in Natural Sciences from the University of Cambridge.

Research interests
  • Metal additive manufacturing
  • Closed-loop control
  • In-process monitoring
  • Metamaterials
  • Functional grading
  • Sustainable manufacture
  • Powder characterisation

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All publications

Journal articles

Conference proceedings papers


Professional activities and memberships


  • Sept 2019. US10416097B2: Method of scanning aerofoil blades. F Freeman, P E Bamforth, R House, T I Simpson
  • Sept 2019. US10416096B2: Method of scanning aerofoil blades. F Freeman, R House, T I Simpson, B Webb
  • July 2019. US10357823B2: Investment casting. J S Torpey, G Durrant, F Freeman
  • Aug 2018. US10055830B2: Pass fail sentencing of hollow components. G Durrant, S J Wagner, F Freeman
Videos and Outreach

Microstructurally Graded Lattices for Tailored Mechanical Response

Alloys for Additive Manufacturing Symposium (AAMS), Munich, Germany, October 2022

Beat the Machine (Learning)

An outreach app to illustrate the use of closed-loop control for improved additive manufacturing

Further details and pseudo-code available in https://doi.org/10.1088/1361-6552/ab9957.

Discover the app