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