Roll-2-Roll (R2R) manufacture of multilayer planar optics
Lead Research Organisation:
University of Southampton
Department Name: Optoelectronics Research Centre (ORC)
Abstract
Optical fibres have transformed our modern world. They form the backbone of our telecommunication network and have enabled high power lasers used in manufacturing. There is a huge amount of technology that is now possible due to the development of the optical fibre.
This project seeks to develop a manufacturing approach for the next generation of optical fibre. Rather than a single flexible strand of glass, we look to manufacture flexible glass sheets. These glass sheets will have similar properties as current optical fibre but the additional width dimension will allow new technology to be realised. For example, the glass sheet can be internally structured to manipulate light. Applications of this ability would include next generation of augmented reality eyewear, quantum computers, telecommunication infrastructure and new potentially higher power lasers.
This technology could be transformative for communications, computation and engineering sectors.
This project seeks to develop a manufacturing approach for the next generation of optical fibre. Rather than a single flexible strand of glass, we look to manufacture flexible glass sheets. These glass sheets will have similar properties as current optical fibre but the additional width dimension will allow new technology to be realised. For example, the glass sheet can be internally structured to manipulate light. Applications of this ability would include next generation of augmented reality eyewear, quantum computers, telecommunication infrastructure and new potentially higher power lasers.
This technology could be transformative for communications, computation and engineering sectors.
Publications
Ahmed Q
(2021)
Direct UV written waveguides and Bragg gratings in doped planar silica using a 213 nm laser
in Electronics Letters
Ahmed Q
(2023)
Investigation into the writing dynamics of planar Bragg gratings using pulsed 213 nm radiation
in Optical Materials Express
Anelli F
(2023)
Effects of Curvature on Flexible Bragg Grating in Off-Axis Core: Theory and Experiment
in Journal of Lightwave Technology
Annunziato A
(2021)
Design of Polarization-Maintaining FBGs Using Polyimide Films to Improve Strain-Temperature Sensing in CFRP Laminates
in IEEE Photonics Journal
Falak P
(2023)
Compact high-resolution FBG strain interrogator based on laser-written 3D scattering structure in flat optical fiber.
in Scientific reports
Gow P
(2021)
Microwave consolidation of UV photosensitive doped silica for integrated photonics
in Optical Materials Express
Holmes C
(2022)
Flexible photonics in low stiffness doped silica for use in fibre reinforced polymer composite materials
in Optical Materials
Holmes C
(2022)
Optical switching in glass fibre composite
in Optics & Laser Technology
| Description | 1) development of multilayered glass sheet, that is thinner than a human hair - which can be connected to optical fibre in order to make new sensors for composite material (used in aerospace and renewable energy sector) and lithium-ion battery packs (used in the automotive industry). 2) application of the fused silica glass plate formed as a means to split light, such to reduced the size, weight and cost of optical sensing - demonstrated and patented (patent application 2301076.2). 3) ultra-thin (1/10 th the thickness of a human hair) glass sheets made from borosilicate and methods of coating - this has potential future application for high energy density and safer glass batteries. |
| Exploitation Route | The project explored fusion drawing of multilayered silica. The applications of the findings are what shall be taken forward. There is IP that has been generated and shall be used in a University spin-out company (Asterium Technologies) and funding already garnered (through DARPA / Caltech collaboration). The ability to draw ultra-thin glass sheets a few 10's um thick, was not expected. Looking at Lithium glass in future work this holds massive potential in the area to scale solid state battery manufacture. An EPSRC grant has already been submitted on this, brining in new expertise to assist with the battery chemistry. Monitoring of laminated structures, such as high value composite material and batteries is another important application. This has been demonstrated with pump-prime funding from EPSRC Composites Hub and shall be the focus of another EPSRC research grant. |
| Sectors | Aerospace Defence and Marine Manufacturing including Industrial Biotechology |
| Description | The flat flexible glass sheet developed is the foundation for Patent application 2301076.2, which forms the basis of an emerging University spin-out Asterium Technologies. |
| First Year Of Impact | 2023 |
| Sector | Aerospace, Defence and Marine,Digital/Communication/Information Technologies (including Software),Environment,Transport |
| Impact Types | Economic |
| Description | BAE Systems iCASE PhD Studentships |
| Amount | £119,000 (GBP) |
| Organisation | BAE Systems |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 09/2022 |
| End | 04/2026 |
| Description | Fiber-Like Optical Loss on Silicon for Ultra-low Loss PlanarWaveguide Circuits |
| Amount | $500,000 (USD) |
| Organisation | Defense Advanced Research Projects Agency (DARPA) |
| Sector | Public |
| Country | United States |
| Start | 12/2022 |
| End | 09/2023 |
| Description | Novel flat optical fibre sensors for application in process control, evaluation and health monitoring of high value composite assets |
| Amount | £1,648,038 (GBP) |
| Funding ID | EP/Y016920/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 03/2024 |
| End | 03/2027 |
| Description | Roll-2-Roll (R2R) Manufacture Of Multilayer Solid-state Batteries |
| Amount | £1,050,233 (GBP) |
| Funding ID | EP/Y008278/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 02/2024 |
| End | 01/2027 |
| Description | EPSRC Future Composites Hub - Synergy Partnership |
| Organisation | Glyndwr University |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | This collaboration between the University of Southampton, University of Bristol and University of Wrexham Glyndwr has taken the flexible glass sheet developed in Roll-2-Roll and sought application for composite material (carbon fibre / glass fibre reinforced polymer) monitoring during manufacture. This was funded by EPSRC Future Composite Manufacturing Research Hub. The glass developed in Roll-2-Roll is offering new insight and monitoring capability to composite manufacture. |
| Collaborator Contribution | University of Bristol and University of Wrexham Glyndwr have expertise in composite material manufacture and mechanical testing. There expertise was combined with my teams expertise in optical sensing and optical manufacture to derive new insight and sensor capability in that field. |
| Impact | One conference output (C. Holmes et. al. Flexible photonics embedded into advanced composites. In 2021 Conference on Lasers and Electro-Optics Europe and European Quantum Electronics Conference, CLEO/Europe-EQEC 2021) and presentation at EPSRC Future Composites Manufacturing Research Hub Synergy Promotion Fund Event (23rd Feb 2022, Hilton Hotel, East Midland Airport) Multidisciplinary: Photonics - Composite Material - Experimental Mechanics |
| Start Year | 2021 |
| Description | EPSRC Future Composites Hub - Synergy Partnership |
| Organisation | University of Bristol |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | This collaboration between the University of Southampton, University of Bristol and University of Wrexham Glyndwr has taken the flexible glass sheet developed in Roll-2-Roll and sought application for composite material (carbon fibre / glass fibre reinforced polymer) monitoring during manufacture. This was funded by EPSRC Future Composite Manufacturing Research Hub. The glass developed in Roll-2-Roll is offering new insight and monitoring capability to composite manufacture. |
| Collaborator Contribution | University of Bristol and University of Wrexham Glyndwr have expertise in composite material manufacture and mechanical testing. There expertise was combined with my teams expertise in optical sensing and optical manufacture to derive new insight and sensor capability in that field. |
| Impact | One conference output (C. Holmes et. al. Flexible photonics embedded into advanced composites. In 2021 Conference on Lasers and Electro-Optics Europe and European Quantum Electronics Conference, CLEO/Europe-EQEC 2021) and presentation at EPSRC Future Composites Manufacturing Research Hub Synergy Promotion Fund Event (23rd Feb 2022, Hilton Hotel, East Midland Airport) Multidisciplinary: Photonics - Composite Material - Experimental Mechanics |
| Start Year | 2021 |
| Description | Impact Acceleration Award - EPSRC/University of Southampton |
| Organisation | GE Aviation Systems |
| Country | United States |
| Sector | Private |
| PI Contribution | Here we put the developed flexible glass sheets into carbon fibre reinforced polymer (composite material) and used technique developed by another team at the University of Southampton to couple light out from the surface of the composite material, overcoming persistent challenges surrounding optical fibre egress that has widely limited commercial adoption of optical-based structural health monitoring (namely fragility of composite egress) |
| Collaborator Contribution | University of Bristol - Composite and mechanical testing Expertise GE Aviation - Industrial pull for composite monitoring / industrial guidance |
| Impact | IP in draft for patent filing Multidisciplinary: - Photonics - Experimental Mechanics - Composite Materials |
| Start Year | 2021 |
| Description | Impact Acceleration Award - EPSRC/University of Southampton |
| Organisation | University of Bristol |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Here we put the developed flexible glass sheets into carbon fibre reinforced polymer (composite material) and used technique developed by another team at the University of Southampton to couple light out from the surface of the composite material, overcoming persistent challenges surrounding optical fibre egress that has widely limited commercial adoption of optical-based structural health monitoring (namely fragility of composite egress) |
| Collaborator Contribution | University of Bristol - Composite and mechanical testing Expertise GE Aviation - Industrial pull for composite monitoring / industrial guidance |
| Impact | IP in draft for patent filing Multidisciplinary: - Photonics - Experimental Mechanics - Composite Materials |
| Start Year | 2021 |
| Title | Real-Time Through-Thickness and In-Plane Strain Monitoring In Carbon Fibre Reinforced Polymer Composites Using Planar Optical Bragg Gratings |
| Description | Integration of flexible glass sheets into composite material for through-thickness strain monitoring. The flexible glass sheets have been under development through EP/V053213/1. |
| IP Reference | GB1916549.7 |
| Protection | Patent application published |
| Year Protection Granted | |
| Licensed | No |
| Impact | BAE Systems have supported an iCASE PhD studentship (to start 2022). The studentship develops the flexible substrate described in EP/V053213/1 and its application in composite materials described in the patent application. |
| Title | Spectral Interrogator Based Upon Cylindrical and Planar Optical Fibre |
| Description | The technology uses the flexible glass sheet developed under EPSRC grant to make a low cost, lightweight interrogator that uses machine learning and quasi-random scattering features. |
| IP Reference | United Kingdom Patent Application No. 2301076.2 |
| Protection | Patent / Patent application |
| Year Protection Granted | |
| Licensed | No |
| Impact | This IP shall be used and is core to a new University spin-out company, Asterium Technologies, that shall use the advantages of the tech for structural and battery health monitoring of cargo drones. |