Manufacture Using Advanced Powder Processes - MAPP Conventional materials shaping and processing are hugely wasteful and energy intensive. Even with well-structured materials circulation strategies in place to recondition and recycle process scrap, the energy use, CO2 emitted and financial costs associated are ever more prohibitive and unacceptable. We can no longer accept the traditional paradigm of manufacturing where excess energy use and high levels of recycling / down cycling of expensive and resource intensive materials are viewed as inevitable and the norm and must move to a situation where 100% of the starting material is incorporated into engineering products with high confidence in the final critical properties. MAPP's vision is to deliver on the promise of powder-based manufacturing processes to provide low energy, low cost, and low waste high value manufacturing route and products to secure UK manufacturing productivity and growth. MAPP will deliver on the promise of advanced powder processing technologies through creation of new, connected, intelligent, cyber-physical manufacturing environments to achieve 'right first time' product manufacture. Achieving our vision and realising the potential of these technologies will enable us to meet our societal goals of reducing energy consumption, materials use, and CO2 emissions, and our economic goals of increasing productivity, rebalancing the UK's economy, and driving economic growth and wealth creation. We have developed a clear strategy with a collaborative and interdisciplinary research and innovation programme that focuses our collective efforts to deliver new understanding, actions and outcomes across the following themes: 1) Particulate science and innovation. Powders will become active and designed rather than passive elements in their processing. Control of surface state, surface chemistry, structure, bulk chemistry, morphologies and size will result in particles designed for process efficiency / reliability and product performance. Surface control will enable us to protect particles out of process and activate them within. Understanding the influence between particle attributes and processing will widen the limited palette of materials for both current and future manufacturing platforms. 2) Integrated process monitoring, modelling and control technologies. New approaches to powder processing will allow us to handle the inherent variability of particulates and their stochastic behaviours. Insights from advanced in-situ characterisation will enable the development of new monitoring technologies that assure quality, and coupled to modelling approaches allow optimisation and control. Data streaming and processing for adaptive and predictive real-time control will be integral in future manufacturing platforms increasing productivity and confidence. 3) Sustainable and future manufacturing technologies. Our approach will deliver certainty and integrity with final products at net or near net shape with reduced scrap, lower energy use, and lower CO2 emissions. Recoupling the materials science with the manufacturing science will allow us to realise the potential of current technologies and develop new home-grown manufacturing processes, to secure the prosperity of UK industry. MAPP's focused and collaborative research agenda covers emerging powder based manufacturing technologies: spark plasma sintering (SPS), freeze casting, inkjet printing, layer-by-layer manufacture, hot isostatic pressing (HIP), and laser, electron beam, and indirect additive manufacturing (AM). MAPP covers a wide range of engineering materials where powder processing has the clear potential to drive disruptive growth - including advanced ceramics, polymers, metals, with our initial applications in aerospace and energy sectors - but where common problems must be addressed.

The public description for this project has been requested but has not yet been received.

3D Printing elicits tremendous excitement from a broad variety of industry - it offers flexible, personalised and on demand scalable manufacture, affording the opportunity to create new products with geometrical / compositional freedoms and advanced functions that are not possible with traditional manufacturing practices. 3D Printing progresses rapidly: for polymerics, we have seen significant advances in our ability to be able to manufacture highly functional structures with high resolution projection through developments in projection micro stereolithography, multimaterial ink jet printing and two photon polymerisation. There have also been exciting advances in volumetric 3DP with the emergence of Computational Axial Lithography and more recent work such as 'xolo'. Alongside these advances there has also been developments in materials, e.g., in the emergence of '4D printing' using responsive polymers and machine learning / AI on 3DP is beginning to be incorporated into our understanding. The impact of these advances is significant, but 3D printing technology is reaching a tipping point where the multiple streams of effort (materials, design, process, product) must be brought together to overcome the barriers that prevent mass take up by industry, i.e., materials produced can often have poor performance and it is challenging to match them to specific processes, with few options available to change this. Industry in general have not found it easy to adopt this promising technology or exploit advanced functionality of materials or design, and this is particularly true in the biotech industries who we target in this programme grant - there is the will and the aspiration to adopt 3D printing but the challenges in going from concept to realisation are currently too steep. A key challenge stymying the adoption of 3D printing is the ability to go from product idea to product realisation: each step of the workflow (e.g., materials, design, process, product) has significant inter-dependent challenges that means only an integrated approach can ultimately be successful. Industry tells us that they need to go significantly beyond current understanding and that manufacturing products embedded with advanced functionality needs the capability to quickly, predictably, and reliably 'dial up' performance, to meet sector specific needs and specific advanced functionalities. In essence, we need to take a bottom-up, scientific approach to integrate materials, design and process to enable us to produce advanced functional products. It is therefore critical we overcome the challenges associated with identifying, selecting, and processing materials with 3DP in order to facilitate wider adoption of this pivotal manufacturing approach, particularly within the key UK sectors of the economy: regenerative medicine, pharmaceutical and biocatalysis. Our project will consider four Research Challenges (RCs): PRODUCT: How can we exploit 3D printing and advanced polymers to create smart 21st Century products ready for use across multiple sectors? MATERIALS: How can we create the materials that can enable control over advanced functionality / release, that are 3D Printable? DESIGN: How can we use computational / algorithmic approaches to support materials identification / product design? PROCESS: How can we integrate synthesis, screening and manufacturing processes to shorten the development and translation pipeline so that we can 'dial up' materials / properties? By integrating these challenges, and taking a holistic, overarching view on how to realise advanced, highly functional bespoke 3D printed products that have the potential to transform UK high value biotechnology fields and beyond.

The surface topography of a component part can have a profound effect on the function of the part. In tribology, it is the surface interactions that influence such quantities as friction, wear and the lifetime of a component. In fluid dynamics, it is the surface that determines how fluids flow and it affects such properties as aerodynamic lift, therefore, influencing efficiency and fuel consumption of aircraft. Examples of the relationships between the topography of a surface and how that surface functions in use can be found in almost every manufacturing sector, both traditional and high-tech. To control surface topography, and hence the function and/or performance of a component, it must be measured and useful parameters extracted from the measurement data. There are a large number instruments that can measure surface topography, but many of them cannot be used realistically for real-time in-process applications due to the need for scanning in either the lateral axes and/or the vertical axis. There have been developments in area-integrating (scattering) methods for measuring surface topography that can be fast enough to use during a manufacturing process, but these are limited in the height range of surface topography with which they can be used. In conventional machining, there has been a significant research effort to determine the surface topography of the machined parts during the manufacturing process. The dominant technology for this has been machine vision approaches, where a relationship between a texture parameter and an aspect of the measured field from an intensity sensor is determined. Such approaches have two major drawbacks: 1. they are usually applied to surfaces with geometrical features over a limited range and 2. they do not have the benefit of a physical model of the measurement process, i.e. they are purely empirical. As an example, the measurement and characterisation of the surface topography of additive manufactured parts remains a significant challenge, especially where measurement speed may be an issue. Typical metal additive manufactured surfaces have a large range of surface features, with the dominant features often being the weld tracks with typical wavelengths of a few hundred micrometres and amplitudes of a few tens of micrometres; such structures are beyond what can be measured effectively with existing commercial approaches. In the proposed project, we aim to demonstrate that it is possible to measure rough and structured, machined or additive surfaces using a simple, cost-effective real-time measurement system. This will involve the development of a fully rigorous three-dimensional optical scattering model, which will be combined with a machine learning approach to mine optical scattering data for topographic information that is not within the range of commercial scattering instruments. The proposed system could be mounted into a machining or additive operation without slowing down the process, therefore, reducing the cost of many advanced products that require engineered surfaces. To demonstrate the commercial potential of the project outputs, we have several advanced manufacturing partners who will supply industrially relevant case studies and one partner who could act as the commercial exploitation route for the instrument.

High Speed Sintering (HSS) has been invented under EPSRC funded research at Loughborough University. The process allows the manufacture of complex components by sintering powder in successive layers, in a manner similar to an existing commercially valuable Rapid Manufacturing process called Selective Laser Sintering (SLS). At Loughborough we have been able to prove that HSS works when making polymeric parts in a small area (50mmxl00mm). However it is only by making parts over a big area that HSS will be commercially competitive. If we are able to make high strength parts over a much bigger area (280mmx330mm) then HSS should prove to be 10 times faster than SLS and around 5 times cheaper. By successfully making parts on a big area using HSS we are confident that we will be able to convince companies to license the technology (under our patents) and make commercial HSS machines. We have various research projects in progress and in the pipeline to support this work, however the Follow on Fund project is the only work directly aimed at securing a license.