ANNUAL REPORT 2010 - Loughborough University

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6 ‘ For Advanced Manufacturing Areas AddiTivE MANUfACTURiNg some products Additive Manufacturing could offer the perfect manufacturing solution by creating new UK businesses, employment, wealth generation and economic growth ’ PRoF. RIChARD hAgUE AnnuAl RepoRt 2010 The Additive Manufacturing Research Group (AMRG) has pioneered the use of layer-based manufacturing techniques for end-use parts. < From left to Right: Dr Russ Harris; Dr Chris Tuck; Prof. Phill Dickens; Dr Neil Hopkinson; Prof. Richard Hague
Background The Additive Manufacturing Research Group (AMRG) was the first research group in the world to undertake systematic research in the field and has set the agenda in terms of its research approach, which has now been recognised and replicated internationally. Underpinning research has been undertaken in processes (polymers, metals), design and design systems, as well as business implementation effects. Impact has accrued from each of these generic areas, across a diverse range of sectors (auto/aero, sports, construction, consumer, medical, etc) with industrial exploitation being undertaken in all areas. The AMRG is now pioneering the use of layer-based manufacturing for end-use parts. The group The group has over 45 dedicated staff including 5 academics, supported by post-doctoral research associates, PhD students and post-graduate research assistants. The group is also supported by a team of highly skilled technicians and the most comprehensive (and recently fully re-equipped) University-based advanced manufacturing laboratory in the world. The additive equipment base (polymers & metals) is supplemented by a suite of analysis equipment, which is combined in a state of the art facility. Impact The AMRG has pioneered the use of Additive Manufacturing (AM) for production components and assemblies. Prior to this, the AM approach (originally known as Rapid Manufacturing) was simply used for prototyping and tooling applications. Since this shift in approach AM has grown into a $1 billion industry, largely due to an increased interest in manufacturing applications. Its current research activity is supported by a wealth of international companies including AWE, BAE Systems, Bentley, Boeing, Burton Snowboards, EOS, Econolyst, MTT, Objet, Renishaw, Solidica and Virgin Atlantic. Future Research Directions Though leading the international field, AMRG research has been focused on single material, homogenous structures, which at best exhibit some level of ‘passive’ functionality. However, to stay at the cutting edge of AM research, the AMRG has recently undertaken a strategic review of its current activity and a comprehensive assessment of global AM research elsewhere. Following this review, a decision has now been taken to move fundamental research activity away from ‘passive’ AM processes and applications, towards the development of more ‘active’ additive manufacturing systems, materials and products. The concept of ‘active’ AM is to use the ‘layer wise’ approach to add value to a component part during manufacture. This could be by embedding electronics or optics into the parts during production, or by using different materials in the same part to add functions that cannot be achieved in a single manufacturing step using conventional processes. This might be the production of parts with dissimilar mechanical or thermal properties, different functional surface coatings or new Nano-materials that exhibit increased mechanical, electrical or thermal properties. Coupled with the design freedoms inherent in AM, there exists significant potential for transformative and disruptive products to be manufactured, which will sit well with the UK’s high-value added, knowledge-based manufacturing sectors. Additionally, most AM research work is undertaken at the macro scale. However, AM processes really make sense for smallcomplex products. Therefore, combined with the shift to “active” parts/assemblies, there exists significant potential to lend industrialisation to the smaller world – including a shift to the construction of nanodevices. AnnuAl RepoRt 2010 7
Page 1 and 2: ANNUAL REPORT 2010 Innovative Manuf
Page 3 and 4: CONTENTS Executive Summary 4 Advanc
Page 5 and 6: ESTABLiShEd iN 2001, the iMCRC has
Page 7: Highlights Prof. David Williams of
Page 11 and 12: Background Modern manufacturing is
Page 13 and 14: Background Construction, like other
Page 15 and 16: Background The sporting goods marke
Page 17 and 18: Background Current automation syste
Page 19 and 20: Research councils have played an im
Page 21 and 22: 185 219 214 223 263 298 AnnuAl Repo
Page 23 and 24: IMCRC Current RESEARCh ThEMES high
Page 25 and 26: 201 253 256 260 250 202 AnnuAl Annu
Page 27 and 28: IMCRC Current RESEARCh ThEMES Trans
Page 29 and 30: Steering group Membership external
Page 31 and 32: Project Title Start Date End Date T
Page 33 and 34: Name Start Date PhD Title Hannah Ed
Page 35 and 36: COLLABORATORS Industrial Collaborat

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