MANUFACTURING THE FUTURE

EPSRC Centres for

Innovative Manufacturing

Manufacturing the future The Engineering and Physical Sciences Research Council (EPSRC) has sponsored the research and doctoral training skills that underpin UK manufacturing for many years. Our current challenge theme, Manufacturing the Future, promotes a richer, more productive dialogue between the UK’s world-leading manufacturing research base and industry partners, to ensure innovative manufacturing businesses play a significant role in shaping research and taking forward the outputs and outcomes. Manufacturing the Future seeks to create, capture and accelerate the impacts of ground-breaking research for the benefit of the UK economy. We do this through a focus on four key priorities, around which we base our research and training investments: • Innovative Production Processes: Transformative processes and technologies for advanced and emergent manufacturing industries • Manufacturing Informatics: Novel ICT and computer science applied to manufacturing processes and systems • Sustainable Industrial Systems: Technologies and operations to reduce usage of material, water and energy resources by manufacturing industries • Frontier Manufacturing: Translating new scientific insights into future manufacturing processes and systems EPSRC Centres for Innovative Manufacturing are the flagship investments of the Manufacturing the Future theme, covering fields as diverse as regenerative medicine, photonic fibres, composite materials and intelligent automated systems. Co-created between academic and industrial partners, EPSRC Centres are national research centres that act as a focal point for their respective research communities. By working as a national network, the EPSRC Centres maximise the impact of innovative research for the UK; supporting our existing industry sectors and opening up new markets in growth areas of manufacturing that are underpinned by developments in science and engineering research. The EPSRC Centres for Innovative Manufacturing, alongside the High Value Manufacturing Catapult of the Technology Strategy Board, are an integral part of the UK Government’s strategy to support high value manufacturing in the UK. The EPSRC Centres explore the research challenges of importance to UK industries and seek appropriate collaborations with the academic and industrial base to maintain and strengthen the excellence of high-value manufacturing in the UK. For more information, please visit: http://www.epsrc.ac.uk/ourportfolio/themes/manufacturingthefuture

Contact: [email protected] EPSRC, Polaris House, North Star Avenue, Swindon SN2 1ET Telephone: +44 (0) 1793 444000 www.epsrc.ac.uk

EPSRC Centres for Innovative Manufacturing The 12 EPSRC Centres for Innovative Manufacturing: Additive Manufacturing EPSRC Centre for Innovative Manufacturing in Additive Manufacturing: combining multiple materials and functions for complex electrical, optical and structural properties in a single manufacturing process. Advanced Metrology EPSRC Centre for Innovative Manufacturing in Advanced Metrology: creating and developing a ‘factory on the machine’ linking measurement and production to minimise cost and allow ever-increasing complexity and quality in manufacturing. Composites EPSRC Centre for Innovative Manufacturing in Composites: developing the next generation of composite manufacturing processes based on low cost, short cycle times, efficiency and sustainability. Continuous Manufacturing and Crystallisation EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation: better products and processes through continuous manufacturing technology in the chemical process industries. Emergent Macromolecular Therapies EPSRC Centre for Innovative Manufacturing in Emergent Macromolecular Therapies: creating the capabilities to select drug candidates for clinical trials based on clinical efficacy and feasibility to manufacture the drug. Industrial Sustainability EPSRC Centre for Innovative Manufacturing in Industrial Sustainability: rapidly reducing the resource and energy-intensity of the production of existing goods, and investigating options for a redesign of the industrial system. Intelligent Automation EPSRC Centre for Innovative Manufacturing in Intelligent Automation: changing the way manufacturing machinery is designed, operated, supported, upgraded, re-used and retired. Liquid Metal Engineering EPSRC Centre for Innovative Manufacturing in Liquid Metal Engineering: equipping the UK metal-casting industry to become more cost-effective and sustainable, while improving casting quality. Photonics EPSRC Centre for Innovative Manufacturing in Photonics: research into advanced manufacturing of new photonic materials, fibres and components. Regenerative Medicine EPSRC Centre for Innovative Manufacturing in Regenerative Medicine: translating ideas into treatments through pinpointing commercially robust practices and processes. Through-life Engineering Services EPSRC Centre for Innovative Manufacturing in Through-life Engineering Services: enabling the design of high-value systems such as aircraft engines that require less engineering service, and incur less whole life cost than current designs. Ultra Precision EPSRC Centre for Innovative Manufacturing in Ultra Precision: creating ultra precision manufacturing processes and machines capable of producing emerging products of differing scale with nanometre accuracy.

Key Academic and Industrial Partners Academic: University of Nottingham Loughborough University

EPSRC Centre for Innovative Manufacturing in Additive Manufacturing Combining multiple materials and functions for complex electrical, optical and structural properties in a single manufacturing process.

Industrial: 3T RPD Ltd AWE Plc BAE Systems Boeing Company Delcam International Plc Delphi Diesel Systems Ltd Econolyst Ltd EOS GmbH - Electro Optical Systems National Physics Laboratory (NPL) Objet Geometries Ltd Printed Electronics Limited Renishaw Plc Smart Fibres Ltd Solidica Corp

Conceptual demonstrator - topologically optimised part with internal lattice and integrated condition monitoring (mock-up)

TWI Ltd

Further details Using additive manufacturing to create, in a single manufacturing process, multimaterial, multifunctional devices with amalgamated electrical, optical and structural properties. Additive manufacturing allows manufacturer to ‘grow’ high value, custom-designed parts layer by layer — enabling manufacturers to make complex shapes from a wide range of materials without the need for new tools or machinery.

Key Research Challenges • Design systems development for multifunctional additive manufacturing. • Investigating the jetting of biodegradable and other functionalised materials through reactive ink jetting processes. • Consolidating the structural elements of a component with increased speed, resolution and repeatability. • Developing the jetting of conductive and dielectric elements to enable the multifunctional additive systems.

Contact: Professor Richard Hague EPSRC Centre Director Tel: +44 (0) 115 951 3962 Email: [email protected] Web: www.3dp-research.com

• Developing modelling techniques for the jetting of multifunctional devices that can accurately simulate the delivery, deposition and post-deposition behaviour of materials. • Developing two-photon polymerisation of multi-material nano-functionalised structures for sensing applications.

EPSRC Centre for Innovative Manufacturing in Advanced Metrology Creating and developing a ‘factory on the machine’ linking measurement and production to minimise cost and allow ever-increasing complexity and quality in manufacturing.

Key Academic and Industrial Partners Academic: University of Huddersfield National Physical Laboratory (NPL) Science and Technology Facilities Council Industrial: Asquith Butler Ltd Brown, David Corporation Plc Carl Zeiss Ltd Centre for Integrated Photonics (CIP) Cummins Turbo Technologies Machine Tool Technologies Ltd Manufacturing Technologies Association Neuteq Europe Ltd Rank Taylor Hobson Ltd Renishaw Plc Rolls-Royce Plc

Dispersive white light interferometer

Further details Deliver ‘disruptive’ solutions to UK industry in the field of total machining and advanced surfaces: • Elevation of machine tool accuracies beyond the present formidable barriers on machine tools. • Building sound foundations for the ‘factory on the machine’ by developing new metrology technologies, to be used within the machine environment. This could be critical in developing a sustainable manufacturing sector, enabling industry to develop the next generation of engineered products dependent on high levels of precision and accuracy.

Key Research Challenges • Efficient, calibration and adjustment of machine tools to a high level of confidence. • Fusion with endogenous sensors and extrinsic measurement for adaptive control. • Fundamental principles and operations for on/in-line measurement of advanced surfaces. • Integrate all developed technologies into the ‘factory on the machine’ environment.

Contact: Professor Xiangquian (Jane) Jiang EPSRC Centre Director Tel: +44 (0) 1484 473634 Email: [email protected] Web: http://www.hud.ac.uk/cimam/

Key Academic and Industrial Partners Academic: University of Nottingham University of Bristol

EPSRC Centre for Innovative Manufacturing in Composites Developing the next generation of composite manufacturing processes based on low-cost, short cycle times, efficiency and sustainability.

Cranfield University University of Manchester Industrial: Aerospace: Airbus UK, GKN, RollsRoyce Plc Automotive: Bentley Motors Ltd, Caparo Vehicle Technologies Ltd, Lotus Engineering Ltd Energy: Luxfer Gas Cylinders ltd, Vestas Blades UK Ltd Technology Centres: National Composites Centre (NCC), Manufacturing Technology Centre (MTC)

3D weaving at the University of Manchester

Further details Composites are a critical technology for developing a low carbon economy — by providing lightweight materials for transport systems, and through their use in wind and tidal power machinery.

Key Research Challenges • Process science – integrated modelling approach to define process capability: defect generation, process variability, design/manufacture/cost interactions. • Processing technology – next generation, high-rate manufacturing technologies: rapid deposition, high-speed processing, parts integration.

Contact: Professor Andrew Long EPSRC Centre Director Tel: +44 (0) 115 951 3779 Email: [email protected] Web: http://www.epsrc-cimc.ac.uk/

EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation Better products and processes through continuous manufacturing technology in the chemical process industries.

Key Academic and Industrial Partners Academic: University of Strathclyde University of Bath University of Glasgow Heriot-Watt University Loughborough University University of Edinburgh University of Cambridge Industrial: AMtech AstraZeneca British Salt Chemtrix Croda International Plc DSTL

A continuous oscillatory baffled crystalliser which is being used for continuous crystallisation

Further details • Enable change from batch to fully continuous manufacturing processes for high value chemical products. • Produce better chemical and pharmaceutical products, at lower cost and more sustainably through transformational change in how particles are manufactured. • Increase competitiveness of UK chemical manufacturers through reduced costs and higher value products.

Fujifilm Imaging colorants Genzyme Ltd GlaxoSmithKline Johnson Matthey Lubrizol NiTech Solutions Ltd Novartis Perceptive Engineering Ltd Prosonix Ltd Solid Form Solutions Syngenta

Key Research Challenges • Achieve precise control over manufacturing of solid particles using continuous manufacturing technologies. • Understand the control and exploitation of nucleation and growth of particles via crystallisation under continuous flow. • Develop continuous crystallisation platforms; process analysis tools and strategies to manufacture ‘perfect particles’ for different applications. • Deliver the tools to achieve exquisite control over crystal structure, particle shape and particle size distribution to meet the needs of advanced manufacturing of innovative chemical products. • Continuous manufacture of medicines and nanomaterials with kinetic, cocrystallisation and impurity control. • Understand key particle properties for enhanced formulated product performance. • Manufacturing operations and supply chain management challenges in continuous manufacturing of chemical particles to include: manufacturing operations and supply chain configuration; management control systems and learning from experiences of other industries. • Optimise manufacturing industries operations and supply chain to enable the effective adoption of continuous manufacturing.

Contact: Professor Alastair Florence EPSRC Centre Director Tel: +44 (0) 141 548 4877 (ext 4877) Email: [email protected] Web: www.cmac.ac.uk

Key Academic and Industrial Partners Academic: University College London (including London School of Pharmacy)

EPSRC Centre for Innovative Manufacturing in Emergent Macromolecular Therapies Creating the capabilities to select drug candidates for clinical trials based on clinical efficacy and the feasibility to manufacture the drug.

Imperial College London Industrial: 23 UK and global companies (SME to Blue chip; consultancies, suppliers, discovery companies, contract manufacturers, pharmaceutical companies) 5 UK network organisations (public associations, trade bodies, KTN) 13 UK and 10 overseas/EU HEIs expressing interest to be feasibility partners

Further details The Centre aims to greatly reduce the time and costs of developing new treatments and improve access to drugs with advanced therapeutic properties. The Centre’s activities will lead to NICE approving many more of the most advanced biopharmaceuticals developed in the UK for use by NHS patients. The developments offer the potential for a step change in the competitiveness and performance of the UKbased biopharmaceutical sector.

Key Research Challenges • Formulate indices for ranking the manufacturability of new molecules. • Link product with process design to facilitate greater process understanding. • Devising lifecycle tools to span the supply chain activities involved, both in the manufacturing and formulation stages and in the healthcare delivery to the patient. • Create optimisation algorithms to handle simultaneous multiple decisions, tradeoffs, constraints and uncertainties.

Contact: Professor Nigel Titchener-Hooker EPSRC Centre Director Tel: +44 (0) 207 679 3796 Email: [email protected] Web: http://www.epsrc-cimmacromoleculartherapies.ac.uk/

• Understand the root causes of poor facility fit through development of advanced multivariate analysis tools.

EPSRC Centre for Innovative Manufacturing in Industrial Sustainability Rapidly reducing the resource and energy-intensity of the production of existing goods, and investigating options for a radical redesign of the industrial system.

Key Academic and Industrial Partners Academic: University of Cambridge Cranfield University Loughborough University Imperial College London Industrial: Adnams Carbon Trust EEF Environmental Sustainability KTN General Motors Company (GM) IBM UK Labs Ltd Institute of Environmental Management and Assessment (IEMA) Marks and Spencer RiverSimple Toyota Motor Europe NV/SA Trade Union Congress (TUC) Unilever Corporate Research

Further details Supporting the development of a sustainable UK industrial system through the provision of knowledge, leaders, tools, methods and policy support, all grounded in practice.

Vitsoe WRAP Xeros Ltd

Delivering tools and techniques that improve current national performance and support the transition to next-generation factories. Envisioning the future shape of low-carbon industrial systems.

Key Research Challenges To compete in a global economy we must learn: • How to make current products in a low-carbon, resource-efficient manner. • How to transform our factories and products. • To explore changes to the entire industrial system. These form the key research challenges within industrial sustainability, which we term eco-efficiency, eco-factory and sustainable industrial system.

Contact: Professor Stephen Evans EPSRC Centre Director Tel: +44 (0) 1223 339815 Email: [email protected] or [email protected] Web: www.industrialsustainability.org

Key Academic and Industrial Partners Academic: Loughborough University Cranfield University

EPSRC Centre for Innovative Manufacturing in Intelligent Automation Changing the way manufacturing machinery is designed, operated, supported, upgraded, re-used and retired.

Industrial: Rolls-Royce Plc Airbus Operations Ltd Aero Engine Controls Manufacturing Technology Centre

Robot 2D visual inspection of turbine

Further details Understanding and developing automated processes for high value, difficult to automate processes. The result could be a radical improvement in the effectiveness of manufacturing operations in the automotive and aerospace industries and on a broad range of companies in UK manufacturing supply chains.

Key Research Challenges • Capturing and understanding high-tech human skills. • Use skills information to determine appropriate human-automation solutions. • Intelligent and adaptive automation systems. • Virtual commission and deployment of automation solutions.

Contact: Professor Mike Jackson EPSRC Centre Director Tel: +44 (0) 1509 227570 Email: [email protected]

EPSRC Centre for Innovative Manufacturing in Liquid Metal Engineering Equipping the UK metal-casting industry to become more cost-effective and sustainable, while improving casting quality.

Key Academic and Industrial Partners Academic: Brunel University University of Birmingham University of Oxford Industrial: Aeromet International plc Constellium Doncasters Group Ltd DSTL Foseco International Ltd Grainger and Worral Ltd Jaguar Land Rover JVM Castings Limited London & Scandinavian Metallurgical Co Ltd (LSM) Magnesium Elektron Meridian Business Development UK New Pro Foundries Ltd

Further details The EPSRC Centre for Innovative Manufacturing in Liquid Metal Engineering, is the national centre in liquid metal engineering. It is based at Brunel University in collaboration with the universities of Birmingham and Oxford. The Centre aims to become the international leader in liquid metal engineering to underpin solidification research, strategic technology developments and user-led industrial applications.

Norton Aluminium Ltd Rautomead Limited Rolls-Royce plc Sandvik Materials Technology Sapa Profiles UK Limited Siemens Metal Technologies

It combines the major UK university centres of light metal casting excellence. Their long-term vision for the global metallurgical industry is that the demand for metallic materials should be met by the full circulation of secondary metals with only limited addition of primary metals each year. This can only be achieved by the effective reuse, and remanufacture of end of life components and the effective recovery and closedloop recycling of secondary metals. This represents a paradigm shift for metallurgical science, manufacturing technology and the industrial landscape. The Centre will conduct fundamental research to generate world-class knowledge in solidification science to develop and exploit innovative and sustainable technologies to enable the UK metal casting industry and its customers to improve their competitiveness in global markets.

Key Research Challenges • Atomistic mechanisms of heterogeneous nucleation. • Generic technologies for nucleation control. • Master alloys for grain refinement. • Metallic materials for closed-loop recycling. • Casting technologies for closed-loop recycling. • Full circulation of metallic materials through reuse, remanufacture and recycling.

Contact: Professor Zhongyun Fan EPSRC Centre Director Tel: + 44 (0) 1895 266406 Email: [email protected] Web: http://www.lime.ac.uk/

Key Academic and Industrial Partners Academic: University of Southampton

EPSRC Centre for Innovative Manufacturing in Photonics Research into advanced manufacturing of new photonic materials, fibres and components.

Industrial: AWE Plc BAE Systems Fianium Ltd Fibercore Ltd FiberLogix Ltd Gooch & Housego Plc M Squared Lasers Ltd OpTek Systems Oxford Electronics Ltd Schlumberger Selex Galileo Sensoptics Ltd SG Controls SPI Lasers UK Ltd Stratophase Ltd

Photonic technologies are pivotal to our information-rich world, driving immense advances in industries such as; communications, healthcare, transport, defence, the environment and manufacturing

Further details The EPSRC Centre for Innovative Manufacturing in Photonics, at the University of Southampton, has world-class capability for research into advanced manufacturing of new photonic technologies. An important aim of the Centre is to strengthen the UK’s photonics sector within this fast-developing, fiercely competitive global market, by enabling UK firms to introduce innovative yet cost-competitive manufacturing processes and extending their product portfolios.

Key Research Challenges • Silica and non-silica optical fibre materials and structures — communications, laser manufacturing, sensing, infrared fibres, defence countermeasures. • Special fibres and components for ultrafast fibre lasers and their applications — supercontinuum sources, microscopy, materials processing. • Special fibres for emerging markets.

Contacts: Professor David Payne EPSRC Centre Director Tel: +44 (0) 23 8059 3583 Email: [email protected] Dr Wei H Loh Deputy Director Tel: +44 (0) 23 8059 2696 Email: [email protected] Web: www.cimp.soton.ac.uk

EPSRC Centre for Innovative Manufacturing in Regenerative Medicine Translating ideas into treatments through pinpointing commercially robust practices and processes that can improve product development and manufacturing processes.

Key Academic and Industrial Partners Academic: Loughborough University University of Nottingham Keele University Industrial: Agency & Clinician Network Celgene Cellon Cellmedica Chipman Technology Electroforce Systems Group, Bose Corporation Future Health Technologies GE Healthcare Life Sciences Intercytex Pfizer/Neusentis RegenTec ReNeuron

Checking for turbidity 28 days after the sterile fill as part of the cell therapy automated manufacturing facility validation

Ruskinn Technology Smith & Nephew TAP Biosystems

Further details The Centre aims to become the 'go to' place for manufacturing research for this emerging industry. Regenerative medicine covers a wide range of advanced therapies designed to enable damaged, diseased or defective skin, bone and other tissue, and even perhaps organs, to work normally again. Such therapies could mean a healthier, happier, more active and productive population with less pressure on health and social care services.

Tigenix Tissue Growth Technology Trade Associations Unilever Videregen

Key Research Challenges • Manufacturing and automation. • Characterisation and quality. • Delivery and three dimensions. • Clarifying and consolidating our international niche. • Strategic links with China and India. • Working with a fragile emerging industry. • Bridging stem cell science, clinical science and manufacturing technology.

Contact: Professor David Williams EPSRC Centre Director Tel: +44 (0) 1509 227668 Email: [email protected]

Key Academic and Industrial Partners Academic: Cranfield University Durham University

EPSRC Centre for Innovative Manufacturing in Through-life Engineering Services Enabling the design of high value systems such as aircraft engines that require less engineering service, and incur less whole life cost than current designs.

Industrial: ADS Group Ltd Aerospace, Aviation and Defence KTN BAE Systems BSI Bombardier Transportation (UK) Ltd Copernicus Technology Ltd East of England Energy Group EnginSoft UK Ltd GOM UK Ltd Energy Generation and Supply KTN MoD Northrop Grumman Sperry Marine Ltd PRICE Systems International Rolls-Royce Plc Say One Media Ltd Siemens Ltd UK Council for Electronic Business

Further details Supporting high-value manufacturing companies through technologies and processes for improved design and manufacturing for engineering services — particularly in the aerospace, defence, railways, electronics, energy, high-end automotive, marine and healthcare technology sectors. The Centre aim is to provide world-class capability in the UK to enable industry to deliver high-value products having outstanding availability, predictability and reliability with the lowest life cycle cost.

Key Research Challenges The EPSRC Centre will combine innovative research and engineering knowledge to tackle some major research challenges in through-life engineering services: • How do we visualise the service activities to inform the design and manufacturing in the presence and absence of past data, and considering adaptation based on the future use scenarios? • How do we minimise the effort (man-hours) and elapsed time (hours) needed to evaluate and optimise the design options for high-value systems (such as aircraft engines) based on service performance and cost?

Contact: Professor Rajkumar Roy EPSRC Centre Director Tel: +44 (0) 1234 758555 Email: [email protected] Web: www.through-life-engineeringservices.org

EPSRC Centre for Innovative Manufacturing in Ultra Precision Creating ultra precision manufacturing processes and machines capable of producing emerging products of differing scale with nanometre accuracy.

Key Academic and Industrial Partners Academic: Cranfield University University of Cambridge National Physical Laboratory (NPL) Industrial: Five Cinetic Gooch & Housego Hexagon Metrology Ltd M-Solv Ltd Microsharp Corporation Ltd SPI Lasers UK Ltd

Meso scale platform - Ultra Precision 6 axis Compact CNC system for diamond turning/micro-milling

Further details The EPSRC Centre for Innovative Manufacturing in Ultra Precision is led by Cranfield University in collaboration with the University of Cambridge and the National Physical Laboratory. It will foster and accelerate development of emerging high value products through its dedicated production compatible ultra precision process research platforms and internationally-leading research programme. It will facilitate the engagement of the UK precision manufacturing supply chain into the future wealth creating opportunities of emerging sectors.

Key Research Challenges • Create and demonstrate rapid ultra precision and fine feature generation processes for multi-material processing of emerging products including their effective quality control. • Create and demonstrate new mass production chains that apply nano and micro scale features rapidly onto large (and continuous) multi-material substrates, to be proven through flagship projects that establish three uniquely performing production research platforms.

Contact: Professor Paul Shore EPSRC Centre Director Tel: +44 (0) 1234 750111 (ext: 2943) Email: [email protected]

MANUFACTURING THE FUTURE

The Engineering and Physical Sciences Research Council (EPSRC) is the UK’s main agency for funding research in engineering and physical sciences. EPSRC invests around £800million a year in research and postgraduate training to help the nation handle the next generation of technological change. The areas covered range from information technology to structural engineering, and mathematics to materials science. This research forms the basis for future economic development in the UK and improvements for everyone’s health, lifestyle and culture. www.epsrc.ac.uk

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08/2012