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Manufacturing and industry 4.0

Digitally transforming manufacturing processes through automation, data and smart technology
  • https://www.sydney.edu.au/engineering/industry-community/partner-with-us.html Partner with us
  • https://www.sydney.edu.au/engineering/about/our-people.html Our people

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Our researchers develop intelligent production systems that fuse the physical and digital worlds, from robotic assembly lines to AI-driven quality control. By harnessing the game-changing convergence of additive manufacturing, novel materials, automation and digital design, we create factories that are highly efficient, flexible and connected. This theme supports Australia’s adoption of Industry 4.0 – using cyber-physical systems and real-time analytics to modernise industries for global competitiveness and sustainable growth.

Sub themes

Our research spans three strengths across multidisciplinary research

3D and 4D printing technologies

Our research aims to revolutionise manufacturing by creating advanced materials, biomedical implants, and resilient infrastructure components using cutting-edge additive technologies. This theme directly supports our strategy of driving technological innovation, sustainability, and industry collaboration, with applications spanning health, aerospace, transport, and construction.

We are developing nanoscale bone, “designer” titanium alloys, and 3D printed composites for civil and aerospace engineering. We have world-class facilities, including metal, polymer, and ceramic printing to accelerate discovery and translation. Our projects explore sustainable 3D-printed concrete, cold-spray metal printing, and bioprinting approaches that guide stem cells to form tissues, ensuring impact across healthcare, industry, and infrastructure.

Research Impact

This research aims to improve advanced manufacturing methods with a focus on creating sustainable, high-performance materials and components, by using cutting-edge additive technologies such as 3D and 4D printing across metal, polymer, ceramic, and biological systems. This enables customised, stronger, and more sustainable solutions, with broad impact on everyday life, from tailored biomedical implants that heal better, to lighter aircraft parts that reduce fuel use, and low-emission concrete for greener cities.

Our researchers

Professor Hala Zreiqat, Professor Julie Cairney, Dr Li Chang, Professor Qing Li, Professor Gwenaelle Proust

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Digital manufacturing and automation

Our research aims to revolutionise industrial production by integrating robotics, Industrial Internet of Things (IIoT) sensors, and artificial intelligence to create agile, intelligent, and adaptive manufacturing systems. This work supports our overarching strategy to drive innovation through interdisciplinary research and technological advancement, contributing to a digital, sustainable, and healthier future.

We are developing “smart factories” that use digital twin simulations and real-time monitoring to optimise production processes. These systems incorporate autonomous machines and data-driven control algorithms that dynamically adjust operations to improve yield and quality. By embedding IIoT sensors and AI into manufacturing environments, we enable predictive maintenance, adaptive control, and seamless integration across production lines.

We are also advancing the design of agile manufacturing systems capable of rapidly adapting to new product designs or materials. This includes the creation of modular robotic platforms, intelligent automation frameworks, and scalable control architectures. Through collaboration with industry partners and leveraging expertise across engineering disciplines, our work is transforming traditional manufacturing into a responsive, data-rich ecosystem that fosters innovation and efficiency.

Research Impact

This research aims to improve industrial manufacturing systems with a focus on creating agile, intelligent, and adaptive production environments, by integrating robotics, IIoT sensors, and AI to enable real-time monitoring, predictive maintenance, and autonomous control. This leads to greater efficiency, reduced waste, and enhanced flexibility, with real-world benefits such as faster production of medical devices, more resilient infrastructure, and sustainable practices across healthcare, transport, and construction industries.

Our researchers

Professor Athman Bouguettaya, Professor Jinman Kim, Professor Ian Manchester,  Professor Gwenaelle Proust, Professor Salah Sukkarieh, Professor Branka Vucetic, Professor Albert Zomaya,

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Industry 4.0 process optimisation

Our research is focused on transforming industrial operations through the integration of advanced analytics, systems engineering, and digital technologies. We want to enhance productivity, sustainability, and responsiveness across manufacturing and supply chain environments. This aligns with our broader strategy to pioneer research that supports a digital, sustainable, and healthier future.

We are applying systems engineering and project management principles to optimise production planning, supply chains, and operational efficiency. Using real-time data and total quality management techniques, we develop frameworks that reduce waste, downtime, and energy use, ensuring that digital innovations translate into measurable performance improvements. This includes the deployment of predictive analytics and simulation models to support agile decision-making and continuous process refinement.

We also integrate mechanical engineering with project management to help industries implement lean, digitally enhanced workflows. Our work supports the adoption of smart technologies across sectors, enabling scalable and sustainable transformation

Research impact

This research aims to improve industrial process efficiency with a focus on optimising production planning and supply chains, by applying advanced analytics, systems engineering, and real-time data tools. This approach reduces waste and energy use, and helps industries deliver faster, more sustainable products, like quicker delivery times and lower environmental impact in everyday manufacturing.

Our researchers

Professor Ian Manchester, Professor Jennifer Whyte

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Leading Schools

Title : School of Aerospace, Mechanical and Mechatronic Engineering

Description : Pioneering research and education for the next generation of aeronautical, mechanical, materials, robotics and space engineering solutions.

Link URL: https://www.sydney.edu.au/engineering/schools/school-aerospace-mechanical-mechatronic-engineering.html

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Title : School of Biomedical Engineering

Description : Advancing health through cutting-edge research, innovation, and transformative education to shape future biomedical leaders.

Link URL: https://www.sydney.edu.au/engineering/schools/school-biomedical-engineering.html

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Title : School of Chemical and Biomolecular Engineering

Description : Creating resources and technologies to transform industries and developing processes that reduce pollution and protect the world.

Link URL: https://www.sydney.edu.au/engineering/schools/school-of-chemical-and-biomolecular-engineering1.html

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Title : School of Electrical and Computer Engineering

Description : Research across a broad range of fields with emphasis on future energy networks, wireless communications, computer engineering, software engineering, photonics and the Internet of Things.

Link URL: https://www.sydney.edu.au/engineering/schools/school-of-electrical-computer-engineering.html

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Title : School of Project Management

Description : Conducting teaching and research excellence across the areas of aerospace engineering, mechanical engineering and mechatronic engineering.

Link URL: https://www.sydney.edu.au/engineering/schools/school-of-project-management1.html

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Useful links

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