EPSRC Future Composites Manufacturing Research
Hub
2017 - 2024
PositioningMarket analysis by CLF
• UK sector currently worth £2.3bn
• Projected growth to £6bn – £12bn by 2030
Growth potential
• Automotive lightweighting
• Next generation single-aisle aircraft
• Large, lightweight & durable structures – renewables and civils
Requirements
• x10 reduction in manufacturing costs
• x100 increase in productivity
• Doubling of workforce between 2020 & 2030
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Potential UK Market for Composites
Renewables
Oil & Gas
Marine
Construction
Rail
Automotive
Aerospace
Defence
Future Composites Manufacturing Hub
The Hub will underpin the growth potential of the UK Composites sector• Enhance process robustness via understanding of process science• Develop high rate processing technologies for high quality structures
CIMComp IndustryCatapults + RTOs
Knowledge Development
Business Development
Applied Technology Development
TRL 1 TRL 5 TRL 6 TRL 7 TRL 8 TRL 9TRL 3TRL 2 TRL 4
An Integrated Approach
Discover Understand Adapt/Integrate Validate Deploy
EPSRC Innovate UK Industry
Increasing scale, increasing investment
Industry Push:
Align research
with industry
needs
Technology
pull-through
to Industry
• Identify long-term technical needs from all industrial sectors and “translate” them into potential
research lines
• High-potential fundamental technologies at TRL3 to be fully developed for industry at the catapults
Promote a step change in composites manufacturing science and technologies
Feasibility studies
Core projects
Create a pipeline of next generation technologies addressing future industrial needs and developing the national composites strategy
Feasibility studies
Core projects
Train the next generation of composites manufacturing engineers (at least 150 people)
EPSRC funded researchers
Doctoral students funded by universities, industry & catapults
Industrial Doctorate Centre students
Build & grow the national & international communities in design & manufacture of high performance composites
National: Outreach programme and feasibility studies
International: International Researcher Network and 7 international missions
Hub Objectives
Grand Challenges
Enhance process robustness via understanding of process science
Develop high rate processing technologies for high quality structures
Core Projects & Feasibility Studies
High rate
deposition and
rapid
processing
technologies
Design for
manufacture
via validated
simulation
Multifunctional
composites
and integrated
structures
Recycling and
re-use
Inspection and
in-process
evaluation
Research Priorities
Platform Funding
Hub Strategy
Hub Structure
Academic Partners
Hub• The University of Nottingham (host)• The University of Bristol
Spoke Members• Brunel University London• The University of Cambridge• Cranfield University• The University of Edinburgh• The University of Glasgow• Imperial College London• The University of Manchester• The University of Southampton
Industrial Partners
• 23 leading institutions across 11 countries• Share information and developments in the field• Facilitate visits and exchange of people• Establish informal or formal partnerships in research programmes• All have agreed to host visits from staff and students for 3 months
International Research Network
Funding Overview
Core Projects:1. New manufacturing techniques for optimised fibre architectures
(Nottingham and Manchester)
2. Efficient manufacturing of multifunctional composite structures (Bristol and Imperial College)
3. Technologies framework for Automated Dry Fibre Placement (ADFP) (Nottingham and Bristol)
Feasibility Studies: 1. Thermoplastic matrix carbon fibre composite / metallic framework structures manufacturing
(Cranfield)
2. Novel strain based NDE for online inspection & prognostics of structures with processing defects
(Southampton)
High rate
deposition and
rapid
processing
technologies
Design for
manufacture
via validated
simulation
Multifunctional
composites
and integrated
structures
Recycling and
re-use
Inspection and
in-process
evaluation
Initial Projects
1. 'Can a Composite Forming Limit Diagram be Constructed?' Dr Michael Sutcliffe, University of Cambridge
2. Multi-Step Thermoforming of Multi-Cavity, Multi-Axial Advanced Thermoplastic Composite Parts Dr Philip Harrison, University of Glasgow
3. Layer By Layer CuringDr Alex Skordos, Cranfield University
4. Simulation of Forming 3D Curved Sandwich Panels Professor Nick Warrior, University of Nottingham
5. Manufacturing Thermoplastic Fibre Metal Laminates by the In-Situ Polymerisation Route Dr Dipa Roy, University of Edinburgh
6. Active Control of the RTM Process Under Uncertainty Using Fast Algorithms Professor Michael Tretyakov, University of Nottingham
7. Microwave (MW) heating through embedded slotted coaxial cables for composites manufacturing (M-Cable)Dr Mihalis, Brunel University London
8. Acceleration of Monomer Transfer Moulding using MicrowavesProfessor Derek Irvine, University of Nottingham
High rate
deposition and
rapid
processing
technologies
Design for
manufacture
via validated
simulation
Multifunctional
composites
and integrated
structures
Recycling and
re-use
Inspection and
in-process
evaluation
New Feasibility Studies
Core Project 1:New manufacturing techniques for optimised fibre architectures
Objectives
• Establish a computational framework for textile preform optimisation not limited by existing manufacturing processes
• Develop new or modified textile preforming technologies to realise these material forms
• Validate simulation and demonstrate performance benefits to materials suppliers and end-users
Methodology
• Develop Texgen to automatically generate non-standard textile formats
• Couple Texgen to a multi-objective genetic algorithm to optimiseprocessing and mechanical properties
• Produce demonstrator samples using a combination of 3D weaving and robotic fibre placement
• Develop laboratory prototypes for new production technologies to manufacture optimised fibre architectures
Weft tows (12K carbon
fibres)
Z-binder (6K twisted
carbon fibres)
Objectives
• Develop manufacturing processes that integrate multifunctional mass/heat/charge transport capabilities within structural configurations, such as doubly-curved surfaces, sandwich panels, and plates with stiffeners and frames
• Carry out a systems level review, including cost-benefit analysis, to identify the constraints involved in taking some of the multifunctional composites concepts through, from the current very low TRL space, towards industrial application
Methodology
• Study of electrical energy storage capability based on supercapacitors exploiting a hierarchical composite, incorporating carbon aerogel
• Making microbraids of epoxy soluble thermoplastic threads with very thin metal wires to enable the delivery of a pre-determined balance of mechanical, thermal, electrical and self-sensing attributes to a final composite structure
Core Project 2:Manufacturing for structural applications of multifunctional composites
Initial Results
• Micrographs showing microbraids
• Typically less than 1mm diameter
• T300 3k carbon over-braided with titanium (1 to 3) and steel yarns (4 to 6)
3 41 2 5 6
Core Project 3:Automated Dry Fibre PlacementObjectives
• Establish experimental simulation to capture the fundamental behaviour of commercial and experimental dry tow materials during automated lay-up
• Increase ADFP deposition rate without compromising quality
– Explore new material formats to facilitate this
– Establish novel material delivery system for advanced control
• Improve numerical simulation capabilities of ADFP deposition, forming and moulding
Methodology
• Develop dry fibre deposition, based on an understanding of dry fibredeformation mechanics
• Use tack characterisation tests to understand the functional mechanisms behind surface interactions during fibre placement
• Develop a predictive model to determine optimum temperature and laydown rates for optimal binder adhesion
• Use Texgen and commercial flow simulation software to investigate the geometrical effects of including gaps in the lay-up
Feasibility Study:Microwave heating through embedded slotted coaxial cables for composites manufacturing
Objective
• To develop novel tooling containing slotted coaxial cables to deliver uniform microwave heating for rapid cure of composite materials
Methodology
• Simulate the energy output of the slotted coaxial cables and the absorbance of this energy by carbon fibres, either in the tool or in the composite part,
• Produce tools with embedded slotted coaxial cables,
• Manufacture composite laminates using the new concept tools,
• Quality assessment of the produced laminates and
• Efficiency assessment of the new tool compared to conventional heating methods.
Feasibility Study:Simulation of forming 3D curved sandwich panels• Objective - To develop a numerical tool to facilitate the application of a low-cost forming technique for manufacturing
complex, medium-high volume automotive components
• Methodology –Extend existing Abaqus/Excplicit fabric forming models to incorporate deformable core materials, in order to simulate the forming of complex sandwich panels
• This project is supported by Gordon Murray Design
Academic
• Submit a Feasibility Study proposal to one of the calls (£50k for 6 months)
• Develop a successful Feasibility Study into a Core Project and become a Hub Member (Up to £300k for 3 years)
• Supervise a PhD/EngD student funded through the Hub
• Apply for an Innovation Fellowship – 2 year position
Industrial
• Sponsor an EngD student (typically £20k pa for 4 years)– Postgraduate embedded in company – Gain access to taught modules for other company staff
• Sponsor a PhD student (typically £18k pa for 3 years)– Access to university facilities
• Collaborate with an academic to develop a Feasibility study
• Support a Core Project
HVM Catapult
• Collaborate on initial and future Core Projects
• Exploit Hub technology developments to leverage future funding
Future Hub Engagement
Which is right for you or your business?
PhD EngD
Location University Industry (75%)
Supervision Academic Academic + Indust. supervisor
Taught modules No Yes (25%)
Research nature TRL 1-3 TRL 3-5
Typical duration 3 years 4 years
Cost per annum £18k £20k
Total cost £54k £80k
EngD or PhD
Ffion Martin – EngD student, Jaguar Landrover
“I decided to do an EngD after working for 8 years in industry. The EngD gave me an opportunity to perform research within a production environment. Working closely with JLR has ensured that the research is valuable and is contributing to the development of future lightweight vehicle platforms.”
Guy Atkins –Technical Director
“Sponsoring an EngD has already proven to be a great success. After only 6 months we have reduced raw material costs on one of our new product lines by nearly 20%. We’ve gained a huge amount of specialist knowledge that we can transfer across the whole of our business, to improve design, reduce waste and costs.”
Other examples
• AEL, The future of composites for marine applications (University of Bristol)
• Hexcel Leicester, Advanced CFRP simulation for the development of fabric architectures and process improvement (University of Nottingham)
• Hexcel Duxford, Composites optimised for rapid production of aerospace components (Cranfield University)
• NCC, AFP technology material/deposition optimisation (University of Bristol)
• NCC, Automated preforming technologies optimisation and integration (University of Bristol)
• NOV Elmar, Composite to metal joining methodologies for high tensile load applications (University of Bristol)
• Rolls-Royce, Improvements and innovation in Automated Fibre Placement (University of Bristol)
EngD Case Studies
The EPSRC Future Composites Manufacturing
Research Hub
2017 - 2024