Date post: | 21-Oct-2014 |
Category: |
Technology |
View: | 987 times |
Download: | 1 times |
© 2013
Making Stuff (Polymer Innovation)
Ben Wood
Technology Transfer Specialist
© 2013
Ben Wood - Technology Transfer Specialist • Background in technology demonstration of green motorsport
projects • EngD in advanced composite materials • Expertise in additive manufacture and composites
Introductions… Polymer Innovation Team
Kylash Makenji - Knowledge Transfer Specialist • Extensive experience in injection moulding industry • MSc and EngD in polymer processing and decoration • Expert in polymer processing and manufacturing
© 2013
Greg Gibbons – Head of Additive Manufacturing Research • PhD in Physics from University of Warwick • World leading expert in additive manufacturing
Introductions… Polymer Innovation Team
Vannessa Goodship – Principle Research Fellow • Extensive experience in plastics industry • Author of more than a dozen plastics books • Expert in polymer recycling
Martin Worrall – Technology Transfer Technician • Trained CNC Programme Setter at Alvis Vehicles • Extensive experience of technology demonstration
© 2013
Polymer Innovation
We make stuff…
© 2013
“We can work with you to develop new products using innovative polymer technologies”
Polymer Innovation
• Working with new materials
• Developing new processes
• State of the art equipment
© 2013
Polymer Innovation Lifecycle
Growth Maturity Decline
S
ale
s an
d p
rofi
t
© 2013
Polymer Innovation Lifecycle
Prototyping
Low Volume Manufacturing
Adding Functionality
Recycling
Formulating New Materials
© 2013
Polymer Innovation Facilities
130m2 Technology Hall
– Prototyping/3D printing
– Compounding new materials
– Injection moulding
– Printed electronics
– Polymer chemistry
© 2013
Polymer Innovation Demonstrators
Low Volume Manufacturing
• Prototyping
• Getting to production
Adding Functionality
• Plastic electronics
• Smart materials
Recycling
• Identifying properties of waste
• Finding new applications
© 2013
Low Volume - Concept
• Review suitable 3D printing technology
• Assess need for technology
Level 2
• Use of equipment and expertise
• Tooling for low volume production
Level 3
• New manufacturing methods
• Unique products
Level 4
• Prototypes to market products and increase sales
• New methods of manufacture
• Unique components impossible to make any other way
© 2013
Low Volume Concept
• Additive Manufacturing (3D Printing)
– More accessible, fashionable
• Systems from £500
– New applications
• Electronics
• Fashion
© 2013
Low Volume – R&D
• Plasma Transferred Arc/CNC
– Make metal polymer tooling in one additive process
• 3D Photocopying
– Charged particles
© 2013
Low Volume - Project
Challenge
‘Our prototypes are very valuable, but we need to show our products at trade shows’
– International sales
– One-off, heavy components
– Challenges with transport and security
© 2013
Low Volume - Project
• Solution – Knowledge exchange
– Use of IIPSI software and equipment
– Production of high-quality display model • Lightweight
• Low cost
• Kit form
© 2013
Low Volume - Project
• Outcomes
– Reduction in transport costs
– Reduced risk of damage/theft
– Increased knowledge of 3D printing systems
© 2013
Adding Functionality - Concept
• Identify applications
• Review technologies
Level 2
• Use of equipment and expertise
• Initial prototypes
Level 3
• New functional polymer components
Level 4
• Added value to existing products
• New methods of manufacture
• New ‘smart’ components
© 2013
Adding Functionality – R&D
• Spray-on electronics – ‘Electronics in a can’
• Complex printed electronics – Batteries, sensors etc
– PV solar panels
• Shape memory polymers – Active disassembly
© 2013
Adding Functionality – R&D
• Hybrid Nano ALM machine
– Inkjet printed electronics
– Thick, viscous materials
• Ceramics, polymers, metals
• Manufacture of components and electronics in one process
© 2013
Adding Functionality - Project
Challenge:
‘Our customer wants our product to light up’
– LEDs only work with ‘natural’ polymer
– Customer wants range of colours
– Surface needs to light up
© 2013
Adding Functionality - Project
• Solution
– Knowledge exchange
– Use of IIPSI expertise
– Spray-on electronic lighting
– Suitable for low-mid volume production
© 2013
Adding Functionality - Project
• Outcomes
– Knowledge of new manufacturing process embedded within JSC’s technical staff
– Applicable to other products moving forward
– Potential new markets
© 2013
Polymer Recycling - Concept
• Review processes
• Segregation
Level 2
• Test material properties
• Identify potential applications
Level 3
• Reintegrate into raw material stream
Level 4
• Reduce material waste • Reduce landfill costs • Improve carbon footprint • Add value to recycled
material
© 2013
Polymer Recycling - Research
• Recycling of ‘smart’ materials
– Composites
– Solar panels
– Plastic electronics
© 2013
Polymer Recycling - Projects
Challenge:
‘What can we do with 3t/day of waste plastic?’
– Food contamination
– Mixed colours
– Low value
© 2013
Polymer Recycling - Projects
• Solution:
– Manufacture of test samples
– Analysis of properties
– Knowledge exchange
– Applications identified
© 2013
Polymer Recycling - Projects
• Outcome:
– Added value
– Landfill costs reduced
– Environmental footprint improved
© 2013
Funded Research Projects
• Simpact Engineering Ltd
– Simulation and FEA consultancy
• Shorter KTP – simulation of sustainable materials
– 60% funded by TSB
– 6 month project
– Full-time Project Associate
– 10% of a Senior Research Fellow
© 2013
Funded Research Projects
• Project Outcomes
– New job created
– Highest ever annual turnover
– Unique capability in sustainable materials
– New customers/markets
• Follow-on
– IIPSI Internship, 8 weeks
© 2013
How IIPSI Can Help…
• Knowledge Exchange – Expertise focussed on your business
• Access to Equipment and Facilities – ‘Try before you buy’
– Understand benefits and pitfalls
• Individual Projects – R&D Level collaborations
© 2013
Down to the technology hall…
• IIPSI Technology Hall taster session – Rapid tooling
– 3D printing applications
– (Not just manufacturing!)
• Preview of IIPSI equipment – Available for use by West Midlands SMEs
© 2013
BEN WOOD @BENJAMINMWOOD [email protected]
We’d love to hear your project ideas…
“We can work with you to develop new products using innovative polymer technologies”