World-changing Research www.nottingham.ac.uk

The internet of things In the aerospace industry, each component that makes up an engine or aircraft is tracked and monitored digitally, creating a whole life history that can be used to improve performance and safety. As technology becomes more affordable, these digital services are creeping into everyday consumer products as well. With this technology, manufacturers could, for example, monitor washing machine use, gaining a better understanding of energy use or predicting potential problems. This connected technology even in the most mundane objects could lead to a future that some call the ‘Internet of Things’.

Manufacturing in the digital age

Institute for Advanced Manufacturing

Personal computers, the internet, wireless networks and mobile devices have transformed the way we live and work. And as devices become cheaper and increasingly interconnected, digital technology is becoming increasingly embedded in all areas of our lives, from public spaces and buildings to kitchen appliances, furniture and even clothes. This shift towards a world of ubiquitous computing and a convergence between the digital economy and traditional manufacturing, opens up exciting and profitable areas of increasing interest to many companies. Helping organisations to understand these new opportunities are researchers at the Institute for Advanced Manufacturing. Our research into digital technology, and how it is designed and used in manufacturing, is crucial for delivering economic and societal benefits. Areas of research include: • the ‘Internet of Things’ • localised manufacturing/cloud manufacturing • ethics

Cloud manufacturing Setting up a manufacturing business is expensive, but greater digital connectivity could lead to a world where businesses can design and make products across shared cloud-based resources, creating a much more fluid and cost-effective supply chain. Thanks to advances in technology, companies may in the near future send their designs to local manufacturing plants who will make their products closer to consumers as and when they are needed. This could revolutionise the way consumers shop – making goods more readily available and greatly reducing the need for transportation. Researchers at the Institute for Advanced Manufacturing are working in collaboration with Horizon Digital Economy Research, looking at opportunities for creating smaller-scale, localised manufacturing. Horizon is a research institute at The University of Nottingham funded by RCUK, which focuses on the role of ‘always on, always with you’ ubiquitous computing technology. We are considering the shared services and new manufacturing processes enabled when cloud computing combined with ubiquitous computing is used to support the creation of transient virtual teams across business boundaries working to create physical artefacts. For more information visit www.horizon.ac.uk or call 0115 8232554

World-changing Research www.nottingham.ac.uk

Advanced Manufacturing

Institute for Advanced Manufacturing

Complex aerospace components made of advanced materials require innovative manufacturing strategies for delivering high integrity surfaces. We provide world-leading machining strategies and post machining surface analysis.

Drilling/ Tapping/ Milling/Grinding of Ni-based superalloys • Eliminate machining anomalies for the avoidance of premature failure in

service • Develop and validate cutting processes for producing strain free and

damage tolerant surfaces • Demonstrate machining capability to airworthiness authorities • Tool life assessment trials • Cutting fluids evaluation across various cutting processes

Process monitoring capabilities The supervision of machine tools and cutting processes is vital for automated manufacture. This can be achieved via process monitoring for the detection of anomalous events on the machine tools and/or workpiece. Process monitoring can provide warning of workpiece anomalies (eg taps, surface drags) and/or tool damage (eg wear, chipping) to alert the operator when tool changes and/or process adjustments are necessary.

Diamond processing A novel concept of robust generation of preferentially orientated and feature-controlled diamond micro-arrays has been developed and patented. This is based on using pulsed laser ablation to generate micro-features on diamond based tools so that controlled dimensions/arrangements of abrasive grits can be generated.

Waterjet Cutting Abrasive waterjet (AWJ) machining is one of the most promising non-conventional processing methods for difficult-to-cut materials such as advanced aerospace components, ceramic materials, composites and super-abrasives including diamond.

World-changing Research www.nottingham.ac.uk

Additive Manufacturing and 3D Printing

Institute For Advanced Manufacturing

ALSAM The ALSAM project will focus on developing process knowledge, materials and software toolsets for the manufacture of lightweight aluminium lattice structures using selective laser melting.

Diginova A digital revolution in manufacturing needs to be anticipated, understood and supported. Materials and manufacturing industries will transform from their 20th Century analogue roots to their 21st Century digital future. The aim of the Diginova project is to help catalyse this by focusing on innovation for digital fabrication. The research group will lead the investigation of key technology challenges and business drivers.

Contract Research The research group hosting the Centre also carries out bespoke developmental projects, applications research and external supply chain development projects for companies. Past companies have included The Boeing Company, Perkins Engines, BAE Systems, Stratasys Inc., Sony Ericsson, Electrolux and Bentley Motors.

EPSRC Centre for Innovative Manufacturing in Additive Manufacturing The Additive Manufacturing and 3D Printing Research Group hosts the EPSRC Centre for Innovative Manufacturing in Additive Manufacturing, in partnership with Loughborough University. This national centre explores next generation multifunctional additive manufacturing (AM) technologies, materials and design systems Flagship Centre research projects • Design systems development for multifunctional additive manufacturing

• Investigating the jetting of biodegradable and other functionalised materials through reactive ink • Area sintering for multifunctional additive manufacturing • Ultrasonic Consolidation for multifunctional additive manufacturing • Jetting of conductive and dielectric elements to enable multifunctional additive systems

• Developing models that can accurately simulate the delivery, deposition and post-deposition behaviour of materials • Two-photon polymerisation of multi-material nano-functionalised structures for sensing applications

World-changing Research www.nottingham.ac.uk

Composite manufacturing

Institute for Advanced manufacturing

Novel approaches to manufacture of complex geometries This project aims to understand the factors currently limiting cost and quality in automated processing, identify routes to deliver cost-effective, high quality, highly capable composites manufacturing processes across multiple sectors Research activities include: • novel approaches to the manipulation of conventional reinforcement forms • novel material forms that offer the potential for simpler manipulations

Structural joints using embedded inserts Novel fabrication techniques of micro-welding and laser sintering for metals and tow winding and 3D weaving for CFC have the potential to produce load introduction fittings which can be co-moulded with CFC laminates and for some cases eliminate bolting of the fitting. Research activities include: • investigation and development of novel attachment fittings and mouldings

techniques • provide net shape moulded connection points for assembly with no

requirement for a fitting assembly stage

Multi-scale modelling to predict defect formation in liquid composite moulding processes This project objectives are to: • develop meso-scale flow and cure simulation techniques to predict

manufacturing defects arising from material and process variability • develop macro-scale transient flow simulations for a reactive resin system

allowing the range of possible outcomes to be predicted at component scale • develop structural FE analysis for samples and components incorporating

defects to predict their effects on mechanical behaviour • experimentally validate predicted defects at all scales and their effects on

mechanical performance using mechanical testing and state-of-the-art imaging techniques

Innovative multi-material and multi-architecture preforms This project aims to develop novel concepts, processes and machines for complex near-net fibre preforms incorporating multi-functional, multi-materials. This will be achieved through an interdisciplinary approach combining advanced robotics and automation with textile processing science.

Pin array embedded in laminate microstructure

3D weaving with multiple weft insertion

Distribution of fibre angles in ± 45° non-crimp fabric

World-changing Research www.nottingham.ac.uk

Food Manufacturing

Institute for Advanced Manufacturing

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Innovative food manufacturing to:

• meet the challenges of Global Food Security enabling conversion of crops to food • develop the trends of distributed manufacture and process intensification

• create natural, healthy and appetising foods

• innovate new food materials and properties

• create foods designed for optimal nutritional performance through process / ingredient interactions

World-changing Research www.nottingham.ac.uk

Human Factors

Institute for Advanced Manufacturing

ManuVar The University is one of several European partners involved in a series of large multimillion-euro manufacturing related projects. ManuVAR is developing an innovative technology platform and framework to support high-value manual work throughout the product lifecycle. Technologies connect experts at different stages of the lifecycle, including designers, factory workers and maintenance personnel. The project focuses on spacecraft assembly, remote maintenance for trains, heavy machinery assembly and maintenance design, assembly line design for SMEs and training for power plant maintenance. The groundbreaking virtual and augmented reality tools include on-site and remote support for maintenance, ergonomics analysis for designing workplaces, designing and reviewing systems for complex assembly procedures and skills training. Find out more at www.manuvar.eu

VISTRA VISTRA is a project funded by the European Commission which aims at the development of a comprehensive platform for simulation and training of manual assembly processes. The platform will use existing enterprise data structures, from which product and manufacturing data will be captured, updated, enriched and transferred into interoperable knowledge representations. Models of the production process and the products being manufactured and assembled will be used to form the basis of operative training programmes. In turn, feedback from training sessions will be inputted into a knowledge centre, to inform improved manufacturing systems and product designs, especially in terms of their ergonomics, safety and efficiency. Central to VISTRA is the use of interactive, game-based training of complex manual manufacturing processes. Find out more at www.vistra-project.eu.

VR-Hyperspace VR-Hyperspace combines the latest research in neuroscience and psychology with virtual and mixed reality technologies to create positive illusions which support passenger comfort in aircraft of the future. Working closely with air and space craft manufacturers the project looks at future interiors of air cabins 2050 and beyond to enhance comfort levels. Virtual environments will be developed and tested which will enable passengers to feel like they are in an extended or alternative space, looking well and feeling comfortable and able to interact with other people and objects. The results are expected to significantly contribute to future transport needs in the second half of this century. Find out more at www.vr-hyperspace.eu

World-changing Research www.nottingham.ac.uk

Operations, logistics and supply chain management

Institute for Advanced Manufacturing

Design trade-offs in automotive new product development Research has been conducted to improve the understanding of the rationale behind design trade-offs in the context of New Product Development, in the automotive industry. The research identified factors of the design context which have impact on design trade-offs. It also helped to understand the interrelationships between these factors and ranked them in terms of their impact on design trade-offs. A design trade-off can be understood by mapping it on this framework.

The Institute works with a number of organisations in the UK, Europe and Asia, including those in the aerospace, pharmaceutical, consumer goods and telecommunications sectors.

Analysing teamwork

A wide range of companies can improve the way they design and manufacture products through close collaboration with our academic consultants. One such example is one of Europe’s largest domestic appliance manufacturers. The company wanted to experiment with co-locating multifunctional design teams in order to improve the development process and bring products to market more quickly. We were able to analyse how this worked, exploring the efficiencies and inefficiencies and make recommendations for improvements.

Effective order fulfilment in the automotive sector Volume car producers face many challenges in delivering a very high number of variants, or buildable vehicle combinations, to the marketplace. We have worked with Ford of Europe to develop analytical and simulation models to understand how best to match customers with appropriate vehicles from anywhere in the pipeline. Vehicles may be in dealership networks, in vehicle holding compounds, in assembly plants, or be ‘virtual vehicles’ planned for production. Understanding how the number of variants offered affects the performance of these open pipeline fulfilment systems has provided many new insights for effective systems design, management and control.

• logistics and supply chain management

• mass customisation • planning, scheduling and

control

• outsourcing logistics and supply chains • quality management • modelling and simulation technology

Areas of research include: • operations strategy • systems design • collaborative design and new product development

There is a particular focus on looking at how companies design products and the interrelations with manufacturing, supply chain and logistics. Researchers explore the benefits and disadvantages of how teams are located, whether physically or virtually, across different disciplines and how they interact. An important aspect of this is so-called ‘concurrent engineering’, a systematic approach to integrate product design and manufacture that considers all elements of the product lifecycle from a very early stage. This can significantly reduce cost and time to market and is being increasingly used by major manufacturers.

World-changing Research www.nottingham.ac.uk

Regenerative medicine and biomanufacturing

Institute for Advanced Manufacturing

Bioprinting as a novel tool for osteochondral tissue engineering The field of tissue engineering has typically focused on controlling the temporal release of growth factors and other cell signalling molecules, with little consideration of the spatial presentation pattern. The creation of more complex signalling environments would allow the development of more sophisticated and more effective tissue engineering therapies. Additionally, both normal and abnormal developmental and repair processes could be modelled and studied in vitro with a high degree of precision. Researchers are looking at evaluations of the Fab@Home solid freeform fabrication platform for its ability to print scaffolds containing zonal distributions of poly(lactic-co-glycolic acid) (PLGA) microspheres, which can be used for controlled release of growth factors. Structurally, the scaffolds are composed of a second type of PLGA-based microparticle, which is capable of sintering to form porous constructs which are mechanically competent for bone repair. Consideration is also given to the inclusion of an alginate hydrogel phase for cell delivery and patterning. The ultimate aim is to show that bioprinting can deliver ‘all-in-one’ scaffolds for osteochondral repair, which provide appropriate mechanical support, offer spatially and temporally controlled release of multiple proteins and support proliferation, differentiation and extracellular matrix production of multiple cell types.

Developing electrospun scaffolds with tailored geometries Electrospinning is a technique widely used to fabricate fibrous scaffolds for tissue engineering applications. Experimental parameters such as flow rate and applied voltage can be adjusted to influence the morphological aspects of the scaffold. More recently the ability of the collector plate design to influence the geometry of the fibrous scaffolds has been investigated. Researchers are investigating the ability of patterned collectors produced by rapid prototyping, to generate electrospun scaffolds with tailored geometries. The novel three-dimensional scaffold geometries were shown to influence mammalian cell adherence and growth.

Photographic images of printed scaffolds before (left) and after (right) sintering. Top to bottom – microparticles and microspheres sintered in saline, dual material (microparticles and crosslinked alginate) sintered in saline and dual material sintered in calcium chloride. Bottom pair are representative SEM images of the outer surface (left) and cross-section (right) of post-sinter microparticle/microsphere scaffolds

Successfully fabricated resin based collectors with a range different patterns