Dr Dean Callaghan

BEng PhD

Director of engCORE and Mechanical Engineering Lecturer

Faculty of Engineering, Carlow Campus
e: dean.callaghan@setu.ie      t: 059 9175467
ORCID ID:0000-0002-8435-6252    ResearchGate   LinkedIn

  • Research Interests
  • Publications
  • Research Supervision
  • Engagement and Collaboration

Research Interests

Dr. Dean Callaghan has a BEng in Mechanical Engineering from Dublin Institute of Technology and a PhD degree in Photonics for Biomedical force sensing from Dublin Institute of Technology. He was previously a lecturer and with DIT and a researcher with the Photonics Research Centre and the Biomedical Devices and Assistive Technology Research group. He is currently Director of the SETU Carlow Centre of Research and Enterprise for Engineering (engCORE). He leads a team of researchers who bring a diverse range of research skills and industry expertise from various fields through their involvement in industrial engineering and academic based projects over many years.

His research interests and activities are primarily focused on the key limiting factors for successful integration of small scale photonic force sensors into medical devices for minimally invasive robotic surgery (MIRS) and magnetic resonance imaging (MRI) interventions. This includes research into the design and manufacture of metallic and polymeric medical devices and instruments with embedded sensing using additive manufacturing techniques. The integration of embedded sensing into these devices enables real-time temperature and force measurements to be ascertained for the purpose of force control and limitation as well as the characterisation of tissue-instrument interaction forces during surgical interventions.

He is also active in the area of fatigue characterisation of metallic coated optical fibres and additive manufactures components with integrated sensing for aerospace applications. Other areas of interest include the development of numerical models of powder bed additive manufacturing processes with a particular emphasis on thermal distributions and component distortion during component build up.




Peer Reviewed Journal Articles

Manjusha Ramakrishnan, Ginu Rajan, Yuliya Semenova, Dean Callaghan, and Gerald Farrell "Investigation of the effect of vibration amplitude on vibration measurements of polarimetric fiber sensors embedded in composite beams” Smart Mater. Struct. Journal, IOP science, 23, no. 4, 2014.

G. Rajan, D. Callaghan, Y. Semenova, and G. Farrell, "Photonic Crystal Fiber Sensors for Minimally Invasive Surgical Devices," Biomedical Engineering, IEEE Transactions on, vol. 59, pp. 332-338, 2012.

D.J. Callaghan, Mark M. McGrath, Ginu Rajan, Eugene Coyle, Yuliya Semenova and Gerald Farrell “Investigation and experimental measurement of scissor blade cutting forces using fibre Bragg grating sensors” Smart Mater. Struct. Journal, IOP science, 2011.

G. Rajan, D. Callaghan, Y. Semenova, M. McGrath, E. Coyle, and G. Farrell, "A Fiber Bragg Grating-Based All-Fiber Sensing System for Telerobotic Cutting Applications," Sensors Journal, IEEE, vol. 10, pp. 1913-1920, 2010.

D.J. Callaghan, M.M. McGrath and E. Coyle, "A Force Measurement Evaluation Tool for Telerobotic Cutting Applications: Development of an Effective Characterization Platform " International Journal of Mathematical, Physical and Engineering Sciences, vol. 1, pp. 144-150, 2007.

Books and Book Chapters

Ginu Rajan, Dean Callaghan, Yuliya Semenova and Gerald Farrell “Optical Fiber Sensors and Interrogation Systems for Interaction Force Measurements in Minimally Invasive Surgical Devices” Smart Sensors for Industrial Applications, CRC Press, May 2013, ISBN: 9781466568105.

Dean J. Callaghan, Mark M. McGrath, Ginu Rajan, Eugene Coyle, Yuliya Semenova and Gerald Farrell “Analysis of Strain Transfer to FBG’s for Sensorized Telerobotic End-Effector Applications” Advances in Robotic Research. Theory, Implementation, Application. Springer Verlag, Part 3, Pages 65-75, June 2009. ISBN: 978-3-642-01212-9.

Conference Proceedings and Papers

Rose Mary, Andrew Keppel and Dean Callaghan, “Finite Element Modelling of Selective Laser Sintering of TI-6AL-4V alloy with an embedded optical fibre sensor,” 4th CADFEM ANSYS Simulation Conference Ireland & UK, Engineers Ireland, Dublin, 12-13 Oct. 2017.

Rose Mary, Kyriakos Kourousis and Dean Callaghan, " Embedding optical fibres in aerospace metallic components: considerations from an additive manufacturing perspective” 34th International Manufacturing Conference (IMC 34), Institute of Technology Sligo, 30-31 Aug. 2017.

G. Rajan, S. Mathews, D. Callaghan, G. Farrell and G-Ding Peng “Polymer fiber Bragg grating force sensors for minimally invasive surgical devices” Proc. SPIE 9655, Fifth Asia-Pacific Optical Sensors Conference, 96551E (July 1, 2015)

S. Mathews, D. Callaghan, Y. Semenova, G. Rajan, G. Farrell, "Photonic crystal fiber strain sensors for laparoscopic surgical devices", Proc. Photonics Global Conference, Singapore, 13-16 Dec. 2012.

S. J. Mathews, Y. Semenova, G. Rajan, D. Callaghan, and G. Farrell, "Temperature Insensitive Miniature Photonic Crystal Fiber Interferometric (PCFI) Strain Sensors," in International Conference on Fibre Optics and Photonics, p. T2C. 4., Dec. 2012.

D.J. Callaghan, Mark M. McGrath, Ginu Rajan, Eugene Coyle, Yuliya Semenova and Gerald Farrell, “Comparing FBG and PCF Force Sensors in a Laparoscopic Smart Surgical Scissor Instrument” Proceedings of the Joint Workshop on New Technologies for Computer/Robot Assisted Surgery, Graz University of Technology, 11-13 July 2011.

G. Rajan, D. Callaghan, Y. Semenova and G. Farrell, “Miniature Temperature Insensitive Fiber Optic Sensors for Minimally Invasive Surgical Devices”, 21st Int. Conference on Optical Fiber Sensors, Ottowa, 15-19 May 2011.

D.J. Callaghan, M.M. McGrath and E. Coyle, "Measurement of Surgical Instrument-Biological Tissue Interaction Forces: Sensor Requirements" Proceedings of the Fourteenth Annual Conference of Bioengineering in Ireland, pp. 53, Sligo, 2008.

D.J. Callaghan, M.M. McGrath and E. Coyle, "Comparison of Force Sensing Technologies for a Haptic Feedback Application" Proceedings of the Northern Ireland Biomedical Engineering Society 28th Annual Spring Meet, P. 10, University of Ulster, 2008.

D.J. Callaghan, M.M. McGrath and E. Coyle, " Force Measurement Methods in Telerobotic Surgery: Implications for End-Effector Manufacture," 25th International Manufacturing Conference (IMC25), pp. 389-398, Dublin Institute of Technology, 2008.

D.J. Callaghan, and M.M. McGrath, “Real-Time Measurement & Angular Position Control of Horizontal Platforms,” 24th International Manufacturing Conference (IMC24), pp. 1105-1112, Waterford Institute of Technology, 2007.


Research Supervision

Current Research Students

Principle supervisor on an MSc project being conducted by Rose Mary entitled “Characterisation of the Cyclic Fatigue Behaviour of Additive Manufactured Components with Embedded Optical Fibre Sensing”

Co-supervisor with Dr Darren Kavanagh (PI) on an MEng project being conducted by Lukas Korcak entitled “Thermo-Mechanical Stress Analysis of Electromagnetic Coils in Electric Machines with Applications in Renewable Energy Systems”

Co-supervisor with Dr Mark Wylie (PI) an MEng project entitled “ Atherosclerotic Tissue Mocks for purpose of Medical Device Development and Device Efficiency/Injury Classification”

Areas of interest as a supervisor include
  • Photonic stress, strain and temperature measurement
  • Embedded sensing technologies and techniques
  • Additive manufacturing numerical modelling
  • Sustainable energy systems
  • Medical device and surgical instrument design and manufacture

Engagement and Collaboration

Currently collaborating with the South Eastern Applied Materials (SEAM) Technology Gateway and University of Limerick on the investigation the embedment of optical fibres into additive manufactured Nickel and Titanium components.

The engCORE research team collaborate with a number of regional, national and transnational enterprises throughout a range of sectors including: Water & Wastewater treatment, Medical devices, Circuit design, Aviation and Aerospace, Food and Farming, Agri-Tech, Pharmaceutical, Mechanical Design, Sustainable Energy and Manufacturing. These engagements have led to numerous Enterprise Ireland Innovation Partnerships, Commercialisation Fund Technology Development research grants and Irish Research Council Enterprise and Employment based grants being awarded to engCORE and its collaborative partners.