ANNUAL REPORT 2010 - Loughborough University

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