About
Karl Holmes
Postgraduate Researcher
University of Galway
Karl Holmes is a PhD researcher at I-Form based at the University of Galway. His research focuses on Simulation-Driven Design for Additive Manufacturing. He holds a bachelor's degree in Mechanical Engineering with a specialisation in Energy Systems from ATU Galway. After graduating, he joined Xerotech as a Mechanical Design and FEA Engineer, where he worked on optimising battery systems at the component level using advanced simulation techniques. This experience sparked a deeper interest in leveraging simulation to improve design efficiency and precision, ultimately leading to his current research. Karl is developing novel computational methods aimed at reducing the significant delays and inaccuracies associated with traditional finite element analysis (FEA) workflows.
Technical Summary
Karl Holmes' research aims to revolutionise the design process in additive manufacturing by enabling real-time simulation capabilities. Traditional finite element analysis (FEA) methods are often computationally intensive, with simulations taking hours or even days depending on complexity, model size, boundary conditions, and analysis parameters. This creates a significant bottleneck during iterative design phases. To address this challenge, his research investigates real-time, layer-by-layer simulation approaches for additive manufacturing processes—particularly powder bed fusion. The objective is to optimise part orientation and support structures to maximise mechanical performance while minimising material usage, thereby enhancing both efficiency and sustainability.
By integrating open-source platforms such as GIBBON (MATLAB-based) and Julia, he is developing lightweight simulation scripts capable of producing accurate results within seconds. This represents a significant leap forward in simulation-driven design, particularly for industrial applications where minimising downtime is critical. His hands-on experience at Xerotech reinforced the value of such solutions, and he is passionate about pushing the boundaries of real-time engineering simulations.