Computational formulation technique for developing resource and energy efficient functional coatings for foundation industry

In civil and mechanical engineering, the design process is done almost entirely by computer. Similarly, a long-held goal in formulated product (FP) design is to shift from an ad-hoc labour-intensive process towards a more robust and adaptive computer aided formulation (CAF) paradigm. Significant progress has been made over the last two decades in utilizing computational methods to aid in the development of formulated products and materials characterisation and discovery.

The foundation industries in the UK have continued in the face of competition due to their ability to innovate, and add value to the products manufactured in the UK, frequently achieved through the application of a functional coating to address a specific market need. The ability to turn innovations from concept to coating faster, is what will let the foundation industries compete better. The ability to optimize the product and process for cost, quality, energy and material efficiency, without taking more development time is a key enabler for future growth.

This project will take a whole supply chain view on the readiness of digital technologies to augment and enhance the traditional formulation process, and the ability to capture the knowledge of the experts in the process in terms of manufacture of constituents, application process, through a the digital-first process. This consortium, including metals, glass and bulk and speciality chemicals supply chain will seek to demonstrate a digital led approach to preparing a formulation for spray deposition on two different kinds of substrate systems, one for the glass sector, and one for steel. While we will focus on antimicrobial coatings, our approach will derisk similar approaches with many different products, different substrates, different application mechanisms, bringing together national centres of expertise with industry partners. Overall this will enable us to produce high value products at lower cost and with lower energy consumption.