10181523LogiKal Digital Manufacturing Integration Platform for Window & Door SystemsClosedCollaborative R&DInnovate UKThe UK window and door manufacturing sector faces significant inefficiencies, including material waste averaging 18% per manufacturer, daily hours lost to manual data transfer, and a 31% productivity gap versus European competitors. These challenges cost the sector an estimated £450 million annually and limit SMEs' ability to compete effectively. Our project seeks to create a groundbreaking digital integration platform for LogiKal, the UK's leading window and door design software used by 80--90% of aluminium fabricators (Cortizo UK, 2019; BM Aluminium, 2025). The platform creates real-time connectivity between design, manufacturing, and enterprise systems, replacing manual processes with automated, intelligent workflows. Live production feedback and AI-powered optimisation reduce material waste, improve productivity, and support compliance with upcoming digital material passporting and carbon tracking requirements under the 2027 Construction Products Regulation. The solution is specifically designed for SMEs, enabling adoption of Industry 4.0 tools without costly or complex implementation. Fabricators can reduce offcuts, prevent order errors, and respond dynamically to material availability and capacity constraints. Integration with existing ERP and MRP systems ensures rapid adoption across UK manufacturers. Projected operational benefits include: * 30% reduction in material waste, saving approximately £185,000 per medium-sized manufacturer annually (based on our internal and pilot company data) * 25% increase in manufacturing productivity, adding roughly 2,000 units of annual capacity * Reduction in rework and order errors, currently affecting 23% of orders at an average cost of £2,100 per incident Beyond efficiency gains, the platform delivers environmental and social benefits. By optimising PVC, aluminium, and glass usage, it reduces construction material waste, supports recycling, and contributes to carbon emission reduction targets. Economically, it strengthens regional manufacturing, safeguards approximately 500 existing jobs, creates high-skilled roles in software and digital manufacturing, and positions UK SMEs to compete more effectively domestically and in European markets. This feasibility study will validate the technical and commercial viability of the platform, providing a replicable model for resource-efficient, high-performance manufacturing across the UK fenestration sector. By combining practical deployment with AI-driven optimisation, the project demonstrates how digital technology can transform traditional manufacturing processes while delivering measurable economic, environmental, and social impact.